Cryogenic testing of the primary mirror segment of the James Webb Space Telescope. These gold-plated mirror segments (18 in total) use a
beryllium substrate, because beryllium is light, strong and withstands the extreme cold of space. Image credit: NASA/MSFC/David Higginbotham
Dear Members,
Before moving on, in my next piece, to such topics as space mining and ion propulsion drives, I thought it would be fun to take a brief look at beryllium and some of the ways it is used in space.
I was reminded, somewhat circuitously, of the metal the other day when reading the US Congressional Research Service’s (“CRS”) October 2023 update to its paper The Defense Production Act of 1950: History, Authorities, and Considerations
for Congress.
In one section of this, the CRS gives some examples of the use of Title III authorities in 2023. En passant, those that involved minor metals included: $90 million “to support the expansion of domestic mining and production of lithium”; $20.6 million “to increase the domestic production of nickel”; and $15 million “to conduct feasibility studies to
expand cobalt extraction in Idaho.
As readers may recall, back in 2007, the National Academy of Sciences published its research paper Managing Materials for a 21st Century Military. In this, it was noted that: “Most recently, this program [Title III] was used to subsidize the creation
of a primary beryllium processing facility in the U.S. in 2006.” that, as far as the paper’s authors knew, “ … this authority
[had] been utilized only once in the 1980s.” (Since then, of course, it has been used many times, not least both during
COVID-19 and in connection with the Inflation Reduction Act.)
What I did remember, reading the beryllium “Case Study” in Appendix F, was that apart from its use in defense applications (airborne forward-looking infrared systems, etc., etc.), it is also used in “aerospace castings”. And not just those for fighter jets (for example, F-35’s) undercarriages.
Beryllium in Space
First off, despite being very light and having a higher specific impulse than aluminium, beryllium is not used for rocket propulsion. It not only costs more (not a surprise), but it is also extremely poisonous. And, perhaps more importantly, amongst others, boron, carbon, hydrogen and lithium all have a higher specific impulse, i.e. contain more energy.
So what is it used for in space? Actually, a number of things.
James Web Space Telescope
Writing back in 2022 about NASA’s James Web Space Telescope, the US Department of Defense (“DoD”) described that
the telescope’s “historic photos” have been made possible by DoD’s “ … ability to secure strategic and critical materials necessary for the mission. And that: “At the top of that list is the unique element beryllium.”
Quoting from the DoD “Spotlight” on the subject: ‘Building a telescope capable of capturing never-before-seen details of
entire galaxies required the development of a lightweight, durable material that would maintain a stable shape in extreme
conditions during the journey into space. The shift from glass mirrors to beryllium-based mirrors augmented the resolution of the space telescope’s captured imagery.’
The Spotlight went on: ‘”Beryllium is a really good material for that,” said Paul Geithner, deputy project manager for the James Webb Space Telescope based at Goddard Space Flight Center. “It’s really stiff, and once it gets below about negative 300 degrees Fahrenheit, it basically stops shrinking. This is important because Webb, insulated by a sun shield, operates at about [30 kelvins, or negative 406 degrees Fahrenheit] and only experiences temperature swings of plus or minus 30 [kelvins], never reaching a temperature that would cause it to expand.”’
And, perhaps it’ll come as no surprise that, as it concludes its story, the DoD talks about the very Title III authorization for “a new primary beryllium facility” I have mentioned above!
Window Frames and Door Systems
Whilst in its earliest days, NASA used beryllium for the heat shields that protected Mercury spacecraft during re-entry, more recently it h.as used the metal in the Space Shuttle and other space vehicles where “it adds strength, dissipates heat and lightens weight in window frames and door systems.” (Fairly anodyne, but obviously important uses.)
“Come here, Rover!”
Perseverance Rover takes a selfie on Mars. Image: NASA/JPL-Caltech/MSSS , 2021. Aluminium beryllium metal matrix
composite is used in a heat sink to protect the rover’s motors in extreme cold.
However, not just “out there is space”, but also “on the ground” in space. Aluminium beryllium structural fittings were used in the two Mars Rovers, Opportunity and Spirit, to help “protect the rovers on their landings, and then served again to unfold their drive-off ramps.”
In addition, such parts were also used in the vehicles’ rock exploration tools. Twenty years on, an aluminium beryllium metal matrix composite is also enabling the motors of the Perseverance Mars Rover (top right), to keep going in the extreme Martian cold.
Missiles et al.
A number of missiles, in particular intercontinental ballistic missiles (“ICBMs”), are exo-atmospheric and carry nuclear warheads. (Which don’t?) In such weapons, beryllium is used both in the nuclear warheads, as the “pit liner” or reflective material and in the technologies of the missiles themselves.
One particularly interesting use of the metal is in the gyro-scopes (e.g., the gimbals) in their guidance systems. Because the gyroscopes spin at very high speeds, they get very hot. With its light weight and excellent thermal conductivity, beryllium is ideal for dissipating this heat. In addition, with a thermal expansion coefficient less than half that of magnesium, beryllium not only enhances the internal stress distribution of the gyroscope, but also helps ensure minimal unwanted deformation.
Finally, there is the “super stability” of the metal, a crucial property. This is especially the case in “ … in long-range mis-siles where a 1% micron deviation in the center of mass can lead to substantial errors. Beryllium’s ability to quickly restore its original shape and resist oxidation and corrosion ensures a stable, long-lasting structure.”
Further space-related, defense-focused uses of beryllium have included (and sometimes still do include):
- Electrical connector contacts;
- Inner stage joining elements in missile systems;
- Lightweight alloys, sensors and optical systems in satellites;
- Rocket nozzles; and
- Skin panels for rocket boosters
Whilst I am sure there are bound to be other uses of beryllium in space that I don’t know about, I think this is probably enough to be getting on with and to whet readers’ appetites.
In May, I am heading off to Mongolia (whither I have never before been) for a quick trip with my son (his graduation pre-sent). Maybe I’ll be able to visit a mine, I don’t know. But, whatever, I shall report back should I discover (experience) anything that may be of interest to MMTA members.
In the meantime, though, from Cleveland Heights, Ohio, as always , I remain
Yours
Tom
©2024 Tom Butcher
Tom Butcher, formerly Director of ESG there, is now a Mar-keting Advisor at Van Eck Associates Corporation (“VanEck”). The views and opinions expressed herein are the personal views of Tom Butcher are not presented by or associated with VanEck or its affiliated entities. Please note that VanEck may offer investments products that invest in the asset class(es) or securities mentioned herein. This is not an offer to buy or sell, or a recommendation to buy or sell any of the securi-ties/financial instruments mentioned herein.
