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How do you test spacecraft systems in different environments?

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Testing spacecraft systems in different environments is a crucial step in ensuring their reliability and performance in space missions. Different environments pose different challenges and risks for spacecraft systems, such as extreme temperatures, radiation, vacuum, vibration, and shock. In this article, you will learn about some of the methods and facilities used to test spacecraft systems in different environments, and why they are important for aerospace engineering.

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Adrien Fève

Spacecraft Senior Thermal Engineer
Zeynep Kocabas

Compliance Verification Engineer, Safety @ Lilium | M. Sc. Aerospace Engineering
Alexis Castel

Technical Expert - Aerospace Vibroacoustics at ESI Group

1 Thermal Vacuum Testing

One of the most common and important tests for spacecraft systems is thermal vacuum testing, which simulates the conditions of space in terms of temperature and pressure. Thermal vacuum testing exposes the spacecraft systems to cycles of heating and cooling, as well as vacuum levels, that mimic the orbital and interplanetary environments. Thermal vacuum testing helps to verify the thermal design and performance of the spacecraft systems, as well as to identify any potential failures or defects caused by thermal stress or outgassing.

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Adrien Fève

Spacecraft Senior Thermal Engineer
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This test can also be used to get some data points in order to correlate the thermal model of the spacecraft in these specific conditions which can then give more confidence into the flight predictions of the model which can't be simulated in tests on the grounds.

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2 Radiation Testing

Another critical test for spacecraft systems is radiation testing, which simulates the effects of cosmic rays, solar flares, and other sources of radiation on the spacecraft systems. Radiation testing exposes the spacecraft systems to various types and levels of radiation, such as protons, electrons, neutrons, gamma rays, and x-rays, that can damage or degrade the electronic components, materials, and sensors of the spacecraft systems. Radiation testing helps to evaluate the radiation tolerance and shielding of the spacecraft systems, as well as to monitor any changes in performance or functionality due to radiation exposure.

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Zeynep Kocabas

Compliance Verification Engineer, Safety @ Lilium | M. Sc. Aerospace Engineering
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- a good example here can be the single event effects tests - there are already established guidelines on the test methods of single event effects (ESA - ESCC Basic Specification No. 25100)

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3 Vibration Testing

A third essential test for spacecraft systems is vibration testing, which simulates the mechanical loads and stresses that the spacecraft systems experience during launch and separation. Vibration testing exposes the spacecraft systems to different frequencies and amplitudes of vibration, such as sinusoidal, random, or acoustic, that can induce fatigue, cracking, or loosening of the spacecraft systems. Vibration testing helps to validate the structural integrity and robustness of the spacecraft systems, as well as to detect any anomalies or failures caused by vibration.

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4 Shock Testing

A fourth important test for spacecraft systems is shock testing, which simulates the sudden and transient impulses that the spacecraft systems encounter during launch, separation, deployment, or landing. Shock testing exposes the spacecraft systems to different magnitudes and durations of shock, such as pyrotechnic, mechanical, or pneumatic, that can generate high accelerations and forces on the spacecraft systems. Shock testing helps to verify the shock survivability and compatibility of the spacecraft systems, as well as to measure any changes in performance or alignment due to shock.

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5 Electromagnetic Compatibility Testing

A fifth vital test for spacecraft systems is electromagnetic compatibility testing, which simulates the electromagnetic interference and compatibility that the spacecraft systems face in space and on Earth. Electromagnetic compatibility testing exposes the spacecraft systems to different sources and levels of electromagnetic fields, such as radio frequency, microwave, or electrostatic, that can affect or disrupt the operation or communication of the spacecraft systems. Electromagnetic compatibility testing helps to assess the electromagnetic emission and susceptibility of the spacecraft systems, as well as to ensure their compliance with the relevant standards and regulations.

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Adrian Tan

Chartered Engineer | Engineering Project Management | PhD Candidate
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It is in my opinion that EMC is not limited to only system to external stimulus, but also concerns interoperability, while in the intended operating environment.

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6 Functional Testing

A sixth and final test for spacecraft systems is functional testing, which simulates the operational scenarios and modes that the spacecraft systems perform in space. Functional testing exposes the spacecraft systems to different inputs and outputs, such as commands, data, signals, or power, that can trigger or test the functionality or behavior of the spacecraft systems. Functional testing helps to confirm the operational readiness and correctness of the spacecraft systems, as well as to identify any errors or bugs in the software or hardware of the spacecraft systems.

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Zeynep Kocabas

Compliance Verification Engineer, Safety @ Lilium | M. Sc. Aerospace Engineering
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I‘m not totally sure to classify functional testing under the environmental tests unless these functional tests are conducted under the specific environmental conditions (high vibration, high/low temperatures etc..). This is not very well transmitted to the reader in the above section and can create confusion.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Alexis Castel

Technical Expert - Aerospace Vibroacoustics at ESI Group
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One thing to consider is the each test aims at showing compliance with one or several design requirements. Thus, the spacecraft is designed to survive the test more than it is designed to survive the flight. This is pushed to the point that most simulations aim at reproducing a given test, such as random vibration or acoustic loading with a diffuse acoustic field. In the end, spacecraft are designed to survive testing more than surviving a flight. This is because the design requirements are often made to envelope several launch vehicles and may be much more stringent than what is experienced during a flight.

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How do you test spacecraft systems in different environments?

1

2

3

4

5

6

7

1 Thermal Vacuum Testing

2 Radiation Testing

3 Vibration Testing

4 Shock Testing

5 Electromagnetic Compatibility Testing

6 Functional Testing

7 Here’s what else to consider

Aerospace Engineering

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How do you test spacecraft systems in different environments?

1

2

3

4

5

6

7

1 Thermal Vacuum Testing

2 Radiation Testing

3 Vibration Testing

4 Shock Testing

5 Electromagnetic Compatibility Testing

6 Functional Testing

7 Here’s what else to consider

Aerospace Engineering

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