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By NASA
7 min read
A New Alloy is Enabling Ultra-Stable Structures Needed for Exoplanet Discovery
A unique new material that shrinks when it is heated and expands when it is cooled could help enable the ultra-stable space telescopes that future NASA missions require to search for habitable worlds.
Advancements in material technologies are needed to meet the science needs of the next great observatories. These observatories will strive to find, identify, and study exoplanets and their ability to support life. Credit: NASA JPL One of the goals of NASA’s Astrophysics Division is to determine whether we are alone in the universe. NASA’s astrophysics missions seek to answer this question by identifying planets beyond our solar system (exoplanets) that could support life. Over the last two decades, scientists have developed ways to detect atmospheres on exoplanets by closely observing stars through advanced telescopes. As light passes through a planet’s atmosphere or is reflected or emitted from a planet’s surface, telescopes can measure the intensity and spectra (i.e., “color”) of the light, and can detect various shifts in the light caused by gases in the planetary atmosphere. By analyzing these patterns, scientists can determine the types of gasses in the exoplanet’s atmosphere.
Decoding these shifts is no easy task because the exoplanets appear very near their host stars when we observe them, and the starlight is one billion times brighter than the light from an Earth-size exoplanet. To successfully detect habitable exoplanets, NASA’s future Habitable Worlds Observatory will need a contrast ratio of one to one billion (1:1,000,000,000).
Achieving this extreme contrast ratio will require a telescope that is 1,000 times more stable than state-of-the-art space-based observatories like NASA’s James Webb Space Telescope and its forthcoming Nancy Grace Roman Space Telescope. New sensors, system architectures, and materials must be integrated and work in concert for future mission success. A team from the company ALLVAR is collaborating with NASA’s Marshall Space Flight Center and NASA’s Jet Propulsion Laboratory to demonstrate how integration of a new material with unique negative thermal expansion characteristics can help enable ultra-stable telescope structures.
Material stability has always been a limiting factor for observing celestial phenomena. For decades, scientists and engineers have been working to overcome challenges such as micro-creep, thermal expansion, and moisture expansion that detrimentally affect telescope stability. The materials currently used for telescope mirrors and struts have drastically improved the dimensional stability of the great observatories like Webb and Roman, but as indicated in the Decadal Survey on Astronomy and Astrophysics 2020 developed by the National Academies of Sciences, Engineering, and Medicine, they still fall short of the 10 picometer level stability over several hours that will be required for the Habitable Worlds Observatory. For perspective, 10 picometers is roughly 1/10th the diameter of an atom.
NASA’s Nancy Grace Roman Space Telescope sits atop the support structure and instrument payloads. The long black struts holding the telescope’s secondary mirror will contribute roughly 30% of the wave front error while the larger support structure underneath the primary mirror will contribute another 30%.
Credit: NASA/Chris Gunn
Funding from NASA and other sources has enabled this material to transition from the laboratory to the commercial scale. ALLVAR received NASA Small Business Innovative Research (SBIR) funding to scale and integrate a new alloy material into telescope structure demonstrations for potential use on future NASA missions like the Habitable Worlds Observatory. This alloy shrinks when heated and expands when cooled—a property known as negative thermal expansion (NTE). For example, ALLVAR Alloy 30 exhibits a -30 ppm/°C coefficient of thermal expansion (CTE) at room temperature. This means that a 1-meter long piece of this NTE alloy will shrink 0.003 mm for every 1 °C increase in temperature. For comparison, aluminum expands at +23 ppm/°C.
While other materials expand while heated and contract when cooled, ALLVAR Alloy 30 exhibits a negative thermal expansion, which can compensate for the thermal expansion mismatch of other materials. The thermal strain versus temperature is shown for 6061 Aluminum, A286 Stainless Steel, Titanium 6Al-4V, Invar 36, and ALLVAR Alloy 30.
Because it shrinks when other materials expand, ALLVAR Alloy 30 can be used to strategically compensate for the expansion and contraction of other materials. The alloy’s unique NTE property and lack of moisture expansion could enable optic designers to address the stability needs of future telescope structures. Calculations have indicated that integrating ALLVAR Alloy 30 into certain telescope designs could improve thermal stability up to 200 times compared to only using traditional materials like aluminum, titanium, Carbon Fiber Reinforced Polymers (CFRPs), and the nickel–iron alloy, Invar.
The hexapod assembly with six ALLVAR Alloy struts was measured for long-term stability. The stability of the individual struts and the hexapod assembly were measured using interferometry at the University of Florida’s Institute for High Energy Physics and Astrophysics. The struts were found to have a length noise well below the proposed target for the success criteria for the project. Credit: (left) ALLVAR and (right) Simon F. Barke, Ph.D. To demonstrate that negative thermal expansion alloys can enable ultra-stable structures, the ALLVAR team developed a hexapod structure to separate two mirrors made of a commercially available glass ceramic material with ultra-low thermal expansion properties. Invar was bonded to the mirrors and flexures made of Ti6Al4V—a titanium alloy commonly used in aerospace applications—were attached to the Invar. To compensate for the positive CTEs of the Invar and Ti6Al4V components, an NTE ALLVAR Alloy 30 tube was used between the Ti6Al4V flexures to create the struts separating the two mirrors. The natural positive thermal expansion of the Invar and Ti6Al4V components is offset by the negative thermal expansion of the NTE alloy struts, resulting in a structure with an effective zero thermal expansion.
The stability of the structure was evaluated at the University of Florida Institute for High Energy Physics and Astrophysics. The hexapod structure exhibited stability well below the 100 pm/√Hz target and achieved 11 pm/√Hz. This first iteration is close to the 10 pm stability required for the future Habitable Worlds Observatory. A paper and presentation made at the August 2021 Society of Photo-Optical Instrumentation Engineers conference provides details about this analysis.
Furthermore, a series of tests run by NASA Marshall showed that the ultra-stable struts were able to achieve a near-zero thermal expansion that matched the mirrors in the above analysis. This result translates into less than a 5 nm root mean square (rms) change in the mirror’s shape across a 28K temperature change.
The ALLVAR enabled Ultra-Stable Hexapod Assembly undergoing Interferometric Testing between 293K and 265K (right). On the left, the Root Mean Square (RMS) changes in the mirror’s surface shape are visually represented. The three roughly circular red areas are caused by the thermal expansion mismatch of the invar bonding pads with the ZERODUR mirror, while the blue and green sections show little to no changes caused by thermal expansion. The surface diagram shows a less than 5 nanometer RMS change in mirror figure. Credit: NASA’s X-Ray and Cryogenic Facility [XRCF] Beyond ultra-stable structures, the NTE alloy technology has enabled enhanced passive thermal switch performance and has been used to remove the detrimental effects of temperature changes on bolted joints and infrared optics. These applications could impact technologies used in other NASA missions. For example, these new alloys have been integrated into the cryogenic sub-assembly of Roman’s coronagraph technology demonstration. The addition of NTE washers enabled the use of pyrolytic graphite thermal straps for more efficient heat transfer. ALLVAR Alloy 30 is also being used in a high-performance passive thermal switch incorporated into the UC Berkeley Space Science Laboratory’s Lunar Surface Electromagnetics Experiment-Night (LuSEE Night) project aboard Firefly Aerospace’s Blue Ghost Mission 2, which will be delivered to the Moon through NASA’s CLPS (Commercial Lunar Payload Services) initiative. The NTE alloys enabled smaller thermal switch size and greater on-off heat conduction ratios for LuSEE Night.
Through another recent NASA SBIR effort, the ALLVAR team worked with NASA’s Jet Propulsion Laboratory to develop detailed datasets of ALLVAR Alloy 30 material properties. These large datasets include statistically significant material properties such as strength, elastic modulus, fatigue, and thermal conductivity. The team also collected information about less common properties like micro-creep and micro-yield. With these properties characterized, ALLVAR Alloy 30 has cleared a major hurdle towards space-material qualification.
As a spinoff of this NASA-funded work, the team is developing a new alloy with tunable thermal expansion properties that can match other materials or even achieve zero CTE. Thermal expansion mismatch causes dimensional stability and force-load issues that can impact fields such as nuclear engineering, quantum computing, aerospace and defense, optics, fundamental physics, and medical imaging. The potential uses for this new material will likely extend far beyond astronomy. For example, ALLVAR developed washers and spacers, are now commercially available to maintain consistent preloads across extreme temperature ranges in both space and terrestrial environments. These washers and spacers excel at counteracting the thermal expansion and contraction of other materials, ensuring stability for demanding applications.
For additional details, see the entry for this project on NASA TechPort.
Project Lead: Dr. James A. Monroe, ALLVAR
The following NASA organizations sponsored this effort: NASA Astrophysics Division, NASA SBIR Program funded by the Space Technology Mission Directorate (STMD).
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Last Updated Jul 01, 2025 Related Terms
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By USH
In 1992, Dr. Gregory Rogers a NASA flight surgeon and former Chief of Aerospace Medicine witnessed an event that would stay with him for more than three decades. Now, after years of silence, he’s finally revealing the details of a 15-minute encounter that shattered everything he thought he knew about aerospace technology.
With a distinguished career that includes support for 31 space shuttle launches, training as an F-16 pilot, and deep involvement in classified aerospace programs, Dr. Rogers brings unmatched credibility to the conversation. His firsthand account of observing what appeared to be a reverse-engineered craft, emblazoned with "U.S. Air Force" markings, raises profound questions about the true timeline of UAP development and disclosure.
The full interview spans nearly two hours. To help navigate the discussion, here’s a timeline so you can jump to the segments that interest you most.
00:00 Introduction and Dr. Rogers' Unprecedented Credentials 07:25 The 1992 Cape Canaveral Encounter Begins 18:45 Inside the Hangar: First Glimpse of the Craft 26:30 "We Got It From Them" - The Shocking Revelation 35:15 Technical Analysis: Impossible Flight Characteristics 43:40 Electromagnetic Discharges and Advanced Propulsion 52:20 The Cover Story and 33 Years of Silence 1:01:10 Why He's Speaking Out Now: Grush and Fravor's Influence 1:08:45 Bob Lazar Connections and Reverse Engineering Timeline 1:17:20 Flight Surgeon Stories: The Human Side of Classified Work 1:25:50 G-Force Brain Injuries: An Unreported Military Crisis 1:34:30 Columbia Disaster: When Safety Warnings Are Ignored 1:43:15 The Bureaucratic Resistance to Truth 1:50:40 Congressional Testimony and The Path Forward 1:58:25 Final Thoughts: Legacy vs. Truth
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By European Space Agency
Video: 00:04:13 Daniel Neuenschwander, ESA head of Space and Robotic Exploration, explains that Ignis mission will include an ambitious technological and scientific programme with several experiments led by ESA and proposed by the Polish space industry.
On 26 June 2025, ESA project astronaut Sławosz Uznański-Wiśniewski from Poland and his crewmates arrived to the International Space Station on the Axiom-4 mission (Ax-4).
The Polish project astronaut is the second of a new generation of European astronauts to fly on a commercial human spaceflight opportunity with Axiom Space.
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By European Space Agency
At the Living Planet Symposium, attendees have been hearing how ESA’s Next Generation Gravity Mission could provide the first opportunity to directly track a vital ocean circulation system that warms our planet – but is now weakening, risking a possible collapse with far-reaching consequences.
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By NASA
An artist’s concept of NASA’s Orion spacecraft orbiting the Moon while using laser communications technology through the Orion Artemis II Optical Communications System.Credit: NASA/Dave Ryan As NASA prepares for its Artemis II mission, researchers at the agency’s Glenn Research Center in Cleveland are collaborating with The Australian National University (ANU) to prove inventive, cost-saving laser communications technologies in the lunar environment.
Communicating in space usually relies on radio waves, but NASA is exploring laser, or optical, communications, which can send data 10 to 100 times faster to the ground. Instead of radio signals, these systems use infrared light to transmit high-definition video, picture, voice, and science data across vast distances in less time. NASA has proven laser communications during previous technology demonstrations, but Artemis II will be the first crewed mission to attempt using lasers to transmit data from deep space.
To support this effort, researchers working on the agency’s Real Time Optical Receiver (RealTOR) project have developed a cost-effective laser transceiver using commercial-off-the-shelf parts. Earlier this year, NASA Glenn engineers built and tested a replica of the system at the center’s Aerospace Communications Facility, and they are now working with ANU to build a system with the same hardware models to prepare for the university’s Artemis II laser communications demo.
“Australia’s upcoming lunar experiment could showcase the capability, affordability, and reproducibility of the deep space receiver engineered by Glenn,” said Jennifer Downey, co-principal investigator for the RealTOR project at NASA Glenn. “It’s an important step in proving the feasibility of using commercial parts to develop accessible technologies for sustainable exploration beyond Earth.”
During Artemis II, which is scheduled for early 2026, NASA will fly an optical communications system aboard the Orion spacecraft, which will test using lasers to send data across the cosmos. During the mission, NASA will attempt to transmit recorded 4K ultra-high-definition video, flight procedures, pictures, science data, and voice communications from the Moon to Earth.
An artist’s concept of the optical communications ground station at Mount Stromlo Observatory in Canberra, Australia, using laser communications technology.Credit: The Australian National University Nearly 10,000 miles from Cleveland, ANU researchers working at the Mount Stromlo Observatory ground station hope to receive data during Orion’s journey around the Moon using the Glenn-developed transceiver model. This ground station will serve as a test location for the new transceiver design and will not be one of the mission’s primary ground stations. If the test is successful, it will prove that commercial parts can be used to build affordable, scalable space communication systems for future missions to the Moon, Mars, and beyond.
“Engaging with The Australian National University to expand commercial laser communications offerings across the world will further demonstrate how this advanced satellite communications capability is ready to support the agency’s networks and missions as we set our sights on deep space exploration,” said Marie Piasecki, technology portfolio manager for NASA’s Space Communications and Navigation (SCaN) Program.
As NASA continues to investigate the feasibility of using commercial parts to engineer ground stations, Glenn researchers will continue to provide critical support in preparation for Australia’s demonstration.
Strong global partnerships advance technology breakthroughs and are instrumental as NASA expands humanity’s reach from the Moon to Mars, while fueling innovations that improve life on Earth. Through Artemis, NASA will send astronauts to explore the Moon for scientific discovery, economic benefits, and build the foundation for the first crewed missions to Mars.
The Real Time Optical Receiver (RealTOR) team poses for a group photo in the Aerospace Communications Facility at NASA’s Glenn Research Center in Cleveland on Friday, Dec. 13, 2024. From left to right: Peter Simon, Sarah Tedder, John Clapham, Elisa Jager, Yousef Chahine, Michael Marsden, Brian Vyhnalek, and Nathan Wilson.Credit: NASA The RealTOR project is one aspect of the optical communications portfolio within NASA’s SCaN Program, which includes demonstrations and in-space experiment platforms to test the viability of infrared light for sending data to and from space. These include the LCOT (Low-Cost Optical Terminal) project, the Laser Communications Relay Demonstration, and more. NASA Glenn manages the project under the direction of agency’s SCaN Program at NASA Headquarters in Washington.
The Australian National University’s demonstration is supported by the Australian Space Agency Moon to Mars Demonstrator Mission Grant program, which has facilitated operational capability for the Australian Deep Space Optical Ground Station Network.
To learn how space communications and navigation capabilities support every agency mission, visit:
https://www.nasa.gov/communicating-with-missions
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