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The Quest for Corrosion Proof Satellites

October 27, 2025
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Low Earth orbit may seem to be empty area, however for the 1000’s of satellites circling our planet between 95 and 1,900 km up, it is really a surprisingly hostile setting. Each second, these spacecraft are bombarded by extremely reactive oxygen atoms that corrode their surfaces, whereas collisions with atmospheric molecules create drag that regularly pulls them again towards Earth. Most satellites final solely about 5 years earlier than these relentless forces take their toll, and the spacecraft tumbles again by means of the environment. Now, a workforce on the College of Texas in Dallas is creating a protecting coating that might essentially change how lengthy satellites survive in orbit.

Earth's atmosphere from space, showing a blue layer at the stratosphere. It's a hostile environment for any satellite launched into low Earth orbit (Credit : NASA) Earth’s environment from area, displaying a blue layer on the stratosphere. It is a hostile setting for any satellite tv for pc launched into low Earth orbit (Credit score : NASA)

The first wrongdoer damaging spacecraft in low Earth orbit is atomic oxygen. When ultraviolet radiation from the Solar strikes molecular oxygen within the skinny higher environment, it splits the molecules aside into particular person atoms. These single atoms are much more reactive than the secure O₂ molecules we breathe, they usually’re the most typical particles satellites encounter in low Earth orbit. When these atoms collide with spacecraft surfaces, they do not simply bounce off, they bind to the fabric, inflicting oxidation. Basically, satellites are slowly rusting in area.

Past the corrosion drawback, satellites additionally face the problem of drag. Every collision with particles within the environment, whether or not oxygen atoms or different molecules, slows the satellite tv for pc down ever so barely. Over time, these numerous tiny impacts trigger the spacecraft to lose altitude and ultimately fall again to Earth. It is a double risk that engineers have been struggling to deal with: supplies want to withstand each chemical erosion and the bodily forces of atmospheric drag.

The workforce, led by supplies scientist Rafik Addou, is tackling this problem by borrowing strategies from different industries and making use of them in novel methods. One method makes use of atomic layer deposition, a technique initially developed for manufacturing microelectronics. This course of builds up protecting coatings one atomic layer at a time, providing unprecedented management over the fabric’s construction and properties. The precision issues enormously if you’re attempting to create a floor that may stand up to the distinctive circumstances of area.

Schematic illustration of one reaction cycle of the ALD process, using the trimethylaluminium (TMA) -water process to make thin aluminium oxide films as (simplified) example (Credit : By Véronique Cremers, Riikka Puurunen, Jolien Dendooven) Schematic illustration of 1 response cycle of the ALD course of, utilizing the trimethylaluminium (TMA) -water course of to make skinny aluminium oxide movies as (simplified) instance (Credit score : By Véronique Cremers, Riikka Puurunen, Jolien Dendooven)

Their second method, known as sol-gel processing, creates strong supplies from liquid options. This methodology, generally used to make optical coatings just like the anti-reflective layers on eyeglasses, permits researchers to engineer surfaces easy sufficient to minimise atmospheric drag whereas sustaining protecting properties. By combining these approaches, the workforce has developed a coating that, in response to unbiased testing, can stand up to atomic oxygen circumstances much more excessive than these really present in area.

Addou and his colleagues hope their work will allow spacecraft to function in very low Earth orbit, the place the setting is considerably harsher resulting from increased concentrations of atomic oxygen and nitrogen. This area provides benefits for sure purposes however has been largely unusable as a result of supplies degrade so quickly there. If profitable, their protecting coatings may open up new prospects for satellite tv for pc operations on this difficult however probably invaluable orbital zone.

Supply : Engineers developing new protective coating for spacecraft



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