Techniques for Thermo-Mechanical Analysis, Design and Characterization of Space Instrumentation

This doctoral thesis, “Techniques for Thermo-Mechanical Analysis, Design and Characterization of Space Instrumentation”, presents a comprehensive study of thermal control systems (TCS) for space missions, with a focus on exoplanetary exploration. The research integrates theoretical modeling, numerical simulations, and experimental validation to address critical challenges in thermal management for spacecraft payloads operating in extreme environments. The work includes the following key aspects: -Mission Design & Thermal Control : Feasibility analysis of thermal architectures for two ESA mission concepts—EXPOSURE (UV exoplanet spectroscopy) and EXODUS (NIR atmospheric escape studies)—emphasizing passive cooling, multi-layer insulation (MLI), and radiator optimization for L2 Lagrange point orbits. This part adopts an analytical approach to estimate the thermal requirements of the two missions to reach the scientific requirements supporting its feasibility. -ARIEL Mission Analysis: Thermal modeling of ESA’s Atmospheric Remote-sensing Infrared Exoplanet Large-survey (ARIEL) payload using ANSYS and ESATAN-TMS, validating cryogenic (<50 K) stability via V-groove radiators and bipod thermal isolators. This numerical analysis allowed to compare the potentialities of a simplified analysis with the finite element (FEM) and lumped parameter (TMM) approaches. Suggesting a combined use that does not compromise system-level thermal assessment reliability and that demonstrates the complementary nature of both tools, validating the potential of hybrid approaches for critical applications — while highlighting how software selection should be based on informed trade-offs between local accuracy (FEM) and global efficiency (LP), according to specific project requirements. -Material Characterization: Experimental modal analysis of Ni-P coated aluminum mirrors subjected to cryogenic conditions (77 K), quantifying Young’s modulus shifts and frequency response for ultra-stable space telescope applications. In this chapter, an experimental setup was developed for non-invasive modal analysis of the samples, along with a procedure that integrates an experimental approach with the numerical analysis and modeling to derive the material properties. The results revealed non-standard properties of the NiP coating, indicating the need for further in-depth studies on varying coating thicknesses and on manufacturing processes involving different aluminum substrate (AW 6082 T6 and RSA). -Finally, the thesis includes an application of the thermal analysis methods to a non-spatial industrial context. Experimental-computational validation of ZeriCAD injection molds with conformal cooling channels, demonstrating ±2℃ thermal uniformity and 22% cycle time reduction for engineering thermoplastics (e.g. TPU) under industrial processing conditions (ISO 294-4), which would allow for better technical performance while reducing production time and costs.