Space missions are increasingly demanding electronic, electrical, and electromechanical (EEE) components that can withstand extreme environments, none more challenging than cryogenic temperatures, which can sometimes approach 0 Kelvin.
ALTER Technology, a TÜV NORD Group company with over 30 years of experience in the space sector, is at the forefront of this technological frontier. As the Components Procurement Parts Agency (CPPA) for ESA’s ARIEL mission, ALTER is leading the qualification and testing of EEE components for operation in the harshest thermal conditions encountered in space science instruments.
Mission Background: ESA ARIEL
ARIEL (Atmospheric Remote-sensing Infrared Exoplanet Large-survey) is ESA’s Cosmic Vision M4 mission, designed to characterise exoplanets and their host stars. The spacecraft’s payload is split into a Cold Payload Module (PLM) and a Warm Service Module (SVM), with the PLM hosting critical subsystems exposed to temperatures as low as 29K. This environment presents unique challenges for EEE components, requiring rigorous selection and qualification processes.
Figure 1: PLM and SVM configuration
Subsystems and Temperature Ranges
The PLM includes equipment such as the Active Cooler System (ACS), Infrared Spectrometer (AIRS), Fine Guidance System (FGS), and various radiators and harnesses. Each subsystem operates across a specific temperature range, with minimums as low as 29K and maximums up to 323K.
Candidate Components for Cryogenic Testing
ALTER, in collaboration with ESA, has performed a comprehensive analysis to select representative components for cryogenic qualification. The selection criteria included:
- Temperature Extremes: Testing under the most stringent conditions for each family.
- Family Coverage: Ensuring all relevant component types required by specific designs from the users are covered. These include capacitors, resistors, connectors, cables, thermistors, heaters, microcircuits and microswitches) are represented.
Advanced Cryogenic Testing Flow
ALTER’s test flow is designed to simulate mission conditions and assess both thermal stress and operational fatigue, including thermal cycles and extended cryogenic testing of 500h or 1000 h testing at minimum operating temperatures:
Figure 2: Example of Cryogenic sequence applied
State-of-the-Art Equipment
Testing is performed at ALTER’s Madrid facilities using a closed-loop Helium cryostat capable of reaching from 10K to 320K, with vacuum feedthroughs for precise electrical measurements. This setup ensures accurate simulation of space conditions and reliable data collection. Furthermore, due to schedule pressing for the mission, ARIEL management decided to double the cryogenic capabilities by adding a similar He Cryostat to parallelise the activities, as you can see in figure 3.
Characteristics of the Cryostat set-up are numerated as follows:
- Temperature control on Big Cold Finger from 10K
- Chamber diameter 22cm, h=10cm
- Temperature Range 10K to 320K
- Temperature Rate <2K/min
- Vacuum range 10-4 to 10-7 mbar
- Temp sensors for control and monitoring
- Feedthrough for in-vacuum measurement, including Sub-D, optical, SMA up to 18GHz and Rotary/linear motion
- Inside ISO 8 Clean Area
Figure 3: Cryostat set-up
Some pictures of the setups and developments for the cryogenic activities:
Results: From Microswitch to OPA
Each test campaign faces important complexity considering the wide variety of parts, from mechanical switches to complex Operational amplifiers. Each device has undergone a thorough review in terms of test plan from all parties (users involved, ESA and ALTER) before proceeding with the activities, especially important to implement the particulars for each device, like representative PCB and materials for OPA and Resistors/capacitors, mechanical constraints for microswitch, etc.
The results of these cryogenic test campaigns are delivered to ESA and applicable users in ARIEL, but these are also being presented at conferences and symposiums in the coming months. Should you be interested in these cryogenic results and/or future testing on extreme temperatures, so not hesitate to reach out to ALTER as an excellent partner for these capabilities.
ALTER Technology stands out for its:
Comprehensive Cryogenic Testing Services
Covering a wide range of EEE components for space missions.
Innovative Solutions
Including DoEEEt and VirtualLab for digital engineering and testing support.
Expertise in Product Assurance
Trusted by ESA and other agencies for mission-critical procurement and qualification.
Agile Test Campaigns
Grouping components to optimize cost and lead time, with parallel cryostat operation under approval to accelerate qualification.
Conclusion and Next Steps
ALTER’s cryogenic testing program for ARIEL is setting new standards in European space component qualification.
The results provide valuable heritage for future missions, supporting the reliability of EEE parts at extreme temperatures and positioning ALTER as an advanced laboratory for testing at extreme temperatures
Acknowledgements
Special thanks to ESA and ARIEL users for their collaboration and support in test definition and sample provision.
Manuel Morales Domínguez
Manuel has over 15 years of experience in the space industry, specialising in EEE components engineering. He has been involved in a wide range of international projects, with a strong focus on European space missions such as JUICE, Euclid, MTG, and BepiColombo. Deeply interested in emerging technologies, he explores their compatibility with both traditional and NewSpace business models.
