Labyrinth seals, extensively used in space applications, serve to prevent the loss of liquid lubricants and shield satellite subsystems from contamination. These seals are essential for the reliable functioning of bearings and for protecting satellite subsystems from contamination. This study compares analytical predictions of lubricant loss against experimental measurements and computer simulations to optimize labyrinth seal configurations. Analytical models tend to overestimate mass loss by 5–8 times compared to experimental data, indicating limited reliability for complex seal geometries. Simulations using MolFlow+ and COMSOL Multiphysics align closely with experimental results, providing accurate mass loss predictions. Key findings highlight that labyrinth length, width, and surface roughness are critical factors in minimizing evaporative mass loss. Notably, stepped labyrinth seals with relief grooves and optimized step positioning effectively reduce molecular beaming effects and improve sealing performance compared to straight geometries. Effective sealing not only reduces mission failures but also helps to minimize space debris, thereby promoting safer satellite missions.

Tribocorrosion is a degradation phenomenon of material surfaces subjected to the combined action of mechanical loading and corrosion attack caused by the environment. Although corrosive chemical species such as materials like chloride atoms, chlorides, and perchlorates have been detected on the Martian surface, there is a lack of studies of its impact on materials for landed spacecraft and structures that will support surface operations on Mars. Here, we present a series of experiments on the stainless-steel material of the ExoMars 2020 Rosalind Franklin rover wheels. We show how tribocorrosion induced by brines accelerates wear on the materials of the wheels. Our results do not compromise the nominal ExoMars mission but have implications for future long-term surface operations in support of future human exploration or extended robotic missions on Mars.

Lubrication is critical to the efficient and reliable operation of machine elements such as gears, bearings, or any other moving mechanical assembly (MMA). On Earth, machine designers are accustomed to the access of a wide range of liquid lubricants that enable predictable and reliable long-term operations of high performance MMA. In space applications on the other hand, engineers are constrained to a comparatively limited choice of lubricant candidates that can meet the stringent demands of tribosystems operating in a space environment. At the same time, repair or maintenance are seldom options that are possible in space, and consequently lubricant failures are potentially critical. As international space agencies are converging on the goal of establishing a permanently crewed lunar Gateway for human presence on the Moon and eventually onwards to Mars, there is a need for radical improvements in many aspects of space exploration technology, including space tribology and space grade lubricants.  

Liquid lubricants are enablers of high performance. A thin fluid film – even in the submicron scale – is often sufficient to separate opposing surface boundaries from direct contact, and thereby prevent excessive friction and wear. Liquid lubricants are therefore attractive for use in space mechanisms. Unfortunately, liquid lubricants must overcome several issues in order to be effective in the space environment. Vacuum, microgravity, and low temperatures are all factors that oppose the effective supply of liquid lubricants into the tribological contact of MMA. If the tribological contact becomes starved of oil, the surfaces enter the boundary lubrication regime where seizure is an ever-present threat. 

There are very few types of fluids available that meet the stringent space grade lubricant requirements. Perfluoropolyalkylethers (PFPE), or multiply alkylated cyclopentanes (MAC) are two fluids with significant heritage in space applications. These fluids are currently employed as lubricants in a wide range of space applications, as they are rare examples of fluids that meet the high demands on resistance to vacuum outgassing. Unfortunately, these compounds are susceptible to degradation under boundary lubrication conditions, and unlike conventional lubricants employed on Earth, these fluids have poor compatibility with the boundary lubrication additives that are commonly employed in conventional oils. 

Ionic liquids (ILs) have emerged as potential liquid lubricant candidates in space. These synthetic fluids are composed of anions and cations. The resulting ionic interaction enables the substance to have low vapor pressure with relatively low molecular weight. For this reason, ILs have been advocated as one of the candidate lubricants for space applications. When employing ILs as lubricants, the ionic charge provides Coulombic interaction with surfaces to enable the formation of a boundary lubricating film. This is an important part of the IL lubricating mechanism, but successful lubricant performance requires integrating the lubricant candidate into the tribosystem, taking into account operating conditions and environment. Therefore, the boundary film formation should be tunable to the application at hand. Ionic liquids are designable fluids, with properties dependent on the combination of anion and cation as well as incorporated functional groups. 

Based on this background, this work focused on evaluating the feasibility of employing ionic liquid lubricants for space applications. In this thesis, the molecular design of an IL lubricant was described Paper [1], and the resulting hydrocarbon-mimicking ionic liquid (P-SiSO) was evaluated in tribological experiments in boundary lubricated conditions. Boundary film formation by neat P-SiSO was studied  in Paper [2], and in Paper [3] we describe the use of P-SiSO as a multipurpose performance ingredient in MAC. A test methodology was devised in Paper [4] in order to evaluate the lubrication performance under component scale experiments in space relevant conditions. The designed ionic liquid lubricant was evaluated in Paper [5] by the specific methodology. Advanced surface analysis was employed to understand the tribo-mechanism of P-SiSO in both the model scale experiments as well as the component scale. The lubricated surfaces were analyzed in terms of surface topography- and chemistry, and mechanisms of lubrication are discussed. A highly effective boundary film based on ionic adsorption and formation of silicate was observed by these ionic liquids. This thesis demonstrates the feasibility of employing ionic liquids for lubrication of moving mechanical assemblies in space applications. 

Low vapor pressure and several other outstanding properties make room-temperature ionic liquids attractive candidates as lubricants for machine elements in space applications. Ensuring sufficient liquid lubricant supply under space conditions is challenging, and consequently, such tribological systems may operate in boundary lubrication conditions. Under such circumstances, effective lubrication requires the formation of adsorbed or chemically reacted boundary films to prevent excessive friction and wear. In this work, we evaluated hydrocarbon-mimicking ionic liquids, designated P-SiSO, as performance ingredients in multiply alkylated cyclopentane (MAC). The tribological properties under vacuum or various atmospheres (air, nitrogen, carbon dioxide) were measured and analyzed. Thermal vacuum outgassing and electric conductivity were meas- ured to evaluate ‘MAC & P-SiSO’ compatibility to the space environment, including the secondary effects of radiation. Heritage space lubricants—MAC and perfluoroalkyl polyethers (PFPE)—were employed as references. The results corroborate the beneficial lubricating performance of incorporating P-SiSO in MAC, under vacuum as well as under various atmospheres, and demonstrates the feasibility for use as a multifunctional additive in hydrocarbon base oils, for use in space exploration applications.

Liquid lubricants are critical to enable long-life operation of high-performance machinery, such as geared actuators employed in robotics. In space applications, actuator gearboxes must operate in low temperatures, where liquid lubricants face inherent problems related to low temperature rheology. Heaters are relied upon to provide acceptable gearbox temperatures. Unfortunately, heating is energy-intense and does not scale well with increasing mechanism mass and performance. Effective boundary lubrication (BL), on the other hand, can minimize problems of low temperature rheology. BL relies on tribofilm formation over conventional fluid film separation. Effective space grade boundary lubricants can potentially allow for drastically reduced amounts of oil and the accompanying rheological problems. In this work, we describe the design of a methodology to evaluate and analyze tribology of actuator gearboxes operated under cryogenic oil-starved conditions in N2 atmosphere. The devised methodology enables research pertinent to space actuator tribology by accelerated testing and advanced analysis, as demonstrated by a lubricant candidate case study. Complementary microscopy techniques are discussed, and a novel methodology devised for gear internal microstructure analysis by X-ray microtomography (XMT) is presented.

Lubricant starvation leads to the risk of a shift in the lubrication regime from (elasto)hydrodynamic towards boundary conditons. Effective tribofilm formation is essential to limit surface damages in these conditions, but additive technology for space-grade lubricants is lacking. This work evaluates the feasibility of a novel type of multifunctional ionic liquid lubricant, for use with multiply alkylated cyclopentane (MAC). Actuator gearboxes are operated under starved conditions in nitrogen atmosphere to evaluate the effectiveness of the tribofilm forming lubricant (designated P-SiSO). The effectiveness of P-SiSO was evaluated from macro to micro scale in both surface and sub-surface analysis by use of microscopy (optical, interferometric, SEM) and X-ray microtomography (XMT), and mechanisms of effective lubrication are discussed.