For anyone who doesn’t know, back in April 2018, Kasey used the internets to organize a very special marriage proposal at the Johnson Space Center. We had booked a semi-private tour (Level 9 Tour) of the grounds and he managed to get the tour guides in on the surprise. The proposal took place in Mission Control and we were able to meet the entire crew and the acting flight director for the Space Station!
Prior to the proposal, we attended a lunch presentation put on by Head of Strategic Communications, Gordon Andrews. I had the chance to approach Gordon after the lunch and ask him about the lubricant formulations for space machinery. Whatever products NASA uses must be able to withstand temperature shifts of up to 500º! He gave me his card and told me he would help me get in touch with Astro-Materials for the answers to my questions.
This week I was back in Houston visiting Shell and was lucky enough to gain a meeting with Gordon right before my flight back home! Gordon met me just inside the security gate where I hopped in his Tahoe and toured around the base.
Our first stop was to the Space Vehicle Mockup Facility where we saw Astronaut Joe Accaba running through some emergency scenario trainings and the new space suit prototypes being tested.
Gordon grabbed us a conference room where he went into some interesting space facts and discussed his career path to become head of Strategic Communications.
Interesting Space Facts:
- The Space Station is in a constant state of free-fall. It is launched to a maximum heigh of 270-250 nautical miles and falls to around 230 nautical miles before it is re-boosted. This cycle occurs every four months.
- For reference, the Earth is at 100% relative gravity and the Space Station is at 90%. The only reason people and objects have the illusion of weightlessness, is due to the state of free-fall.
- This free-fall state causes liquid to take on rounded droplet/ball like formations. Living cells, such as those in diseases, are better studied in this rounded state.
- This free-fall state also eliminates the process of convection, causing fire to burn differently than it would on Earth.
- Once back on Earth after a lengthy time in space, ISS astronauts, specifically white males, have an issue of fluid collecting and optic nerve degradation at the back of the eye. These symptoms are not found in other races or females and the reason for this is still unknown.
- Astronauts are medically monitored for the rest of their lives after returning to Earth so that we may study the long term effects of space travel on the human body. Without the Earth’s atmospheric shield from cosmic radiation, each astronaut receives the equivalent of 5 chest x-rays of radiation per day. So far, no astronauts have exhibited medical issues from this radiation exposure later in life.
- Four to six resupply ships are sent up to the space station per year. Since there is not yet a way to wash clothing in space, ISS astronauts are required to wear clothing for multiple days until they can swap out dirty clothes for fresh clothes on these resupply loads.
- 500 experiments are conducted per year at 100 hours of research time logged per week.
- All US astronauts are required to learn Russian since we share the ISS with many Russian cosmonauts.
- A seat for an astronaut to hitch a ride up to the ISS on a Russian ship is $80 million each. We usually purchase a group of seats when we ride along.
- Since ice caps were discovered on the moon’s poles, an unmanned rover will be sent to pull core samples of the ice in 2022 ahead of the 2024 human trip. Oxygen and hydrogen are the elements making up water and scientists believe we may be able to harness the hydrogen as a fuel source. This would save us from having to bring so much fuel with us on the trip from Earth.
(Unmanned Moon Rover)
After wrapping up our discussion in the conference room, we hopped back in Gordon’s Tahoe and headed over to the engineering research and development building. The first room we entered was a big open space filled with tools and ongoing experiments. A clean room held three scientists studying vibration limits on an Orbital Maneuvering System engine to determine if it will qualify for use on Orion’s service module. The vibration testing will help ensure the engine can withstand the loads induced by launch on the agency’s Space Launch System rocket.
(Image of vibration analysis taken from the internet since I was unable to take pictures)
We also saw a pressure machine that encased a Space Station window. The window was put into the pressure machine on the same date the ISS was first launched into space and remains under the exact same PSI as the windows currently on the ISS. If something happens due to age/time under pressure to the window in the pressure machine, scientists will be able to prepare for the issue to happen to the windows on the ISS.
(I was unable to find a picture of the pressure chamber)
Gordon proceeded to take me into the office section of the building where engineers were busy at work at their desks. The first person we encountered was able to direct us to the office of accomplished metallurgic engineer John Figert. John was kind enough to give us 10 minutes of his time to discuss the lubricants used on space vessels. To my displeasure, Castrol engineers all of the product lines able to withstand the extreme environments of space (ha!).
The majority of parts needing lubricants in space are bearings and seals. The main greases used are (hang with me here, it gets a bit technical):
- Castrol Braycote 601: A rocket propellant compatible, rust preventative, and low temperature withstanding, perfluorinated polyether grease. This product is nontoxic, nonflammable, CFC free, grease with extremely low volatility. Its temperature range is -112ºF to 400ºF and is effective in vacuum environments. It can be purchased in 2oz & 4oz syringes, 1lb jars, and 1,75oz cartridges. Normal grease tubes for purchase are 10 to 14oz for reference.
- Castrol Braycote 602: A moly disulfide grease that is rocket propellant compatible and has a low temperature withstanding capability. Another perfluorinated polyether grease like its sister product; it is also nonflammable, CFC free, has good sheer stability, and has low acute toxicity. This product contains a gelling agent (tetrafluoroethylene telomer) and is designed to operate in the presence of fuels, oxidizers, and deep space vacuums. Its temperature range is also -112ºF to 400ºF and it can be purchased in 2oz & 4oz syringes, and 1lb jars.
- Castrol Brayco 815Z: A clear water white perfluorinated polyether based fluid. It is virtually inert, compatible with rocket propellants and oxidizers, is unaffected by ultraviolet, cosmic radiation, or high vacuums. It has an exceptionally high viscosity index and low volatility, and has little tendency to form deposits. Its temperature range is -100ºF to 400ºF, but can withstand short periods at 500ºF and is available in 2oz bottles and 1lb jars.
Other products used:
- Dupont Krytox 240AC: A perfluorinated polyether product with temperature ranges of -100°F to 750 °F.
- Nye Lubricants Rheolube 2000 (Bearing grease): Specifically developed for instruments and bearings in aerospace and vacuum applications. These greases consist of multiply alkylated cyclopentane thickened with a sodium soap complex.
- Other Teflon based greases
In case you are wondering:
- Perfluoropolyethers (PFPEs) are a family of fluorinated synthetic fluids that are used to formulate the most thermooxidatively stable lubricants available today. They are slippery, long-chain fluoropolymers that wet surfaces well, making them good materials for lubricants. The layer of fluorine atoms that surround each PFPE molecule makes electron exchange difficult — which keeps oxidation in check. (George Mock of Nye Lubricants)
All of these product are synthetic and cost between $700 and $2000 per oz! They are vital to the proper function of space equipment. Oil is important even in space!
John Figert has many published works that can be found online and teaches a tribology/metallurgy class on the base which has a wait list. He mentioned helping some of the younger researchers discover an issue with bearings destined for lunar operations. These bearings must be heat-treated and put through thermal stabilization processes or else they will experience dimensional changes and fail prematurely in space environments. John began his career in the defense industry and has a very impressive career.
If you are wondering how Gordan Andrews became head of Strategic Communications, he has a great story! He grew up near the Space Center and never really thought about working there. While attending college for Radio/TV/Film Broadcast, he worked at a state park and had no idea how he wanted to start his career after his schooling. A park ranger counterpart mentioned Mission Control was in need of a broadcaster, so he went in for an interview. Gordon says the main reason he got the job was because a radio internship he had worked during school had taught him how to use a specific machine that NASA was also using for its broadcasts. He did shift work in flight control for a while but this was not sustainable with a young family at home, so he then transitioned to a roll in the training of the astronauts. He was also the Dean of NASA’s Space College where he taught five of the 55 required classes. He worked alongside Gene Kranz, and when Gene was retiring, Gordon thought about leaving NASA as well to pursue another path but received a job offer he could not turn down as the communications director for the X38 Experimental space craft program. Gordon then transitioned to his current roll in communications and public relations for both the ISS, NASA Engineering, and most recently the new space suit development program.
Part of his roll involves heading up the production of the new “Down to Earth” NASA Youtube series as well as many NASA related photoshoots, and the up-and-coming 360 NASA Virtual Reality program. I was super excited to hear about this virtual reality program which includes space recordings that VR headset owners can download for a life-like space experience as well as a live-stream VR broadcast from the moons surface coming in 2024! The passion Gordon has for his job was palpable and he has no plans to retire in the near future.
I am so grateful for yet another once-in-a-lifetime experience at the Johnson Space Center and can’t thank my generous host Gordon, as well as John Figert, enough for their time! My sites are now set on a tour of the Kennedy Space Center in Florida this fall.