Results for “Graphite Technology” — Page 12

NASA NTRS2000

Boiling on Microconfigured Composite Surfaces Enhanced

Boiling heat transfer is one of the key technologies for the two-phase active thermal-control system used on space platforms, as well as for the dynamic power systems aboard the International Space Station. Because it is an effective heat transfer mode, boiling is integral to many space applications, such as heat exchangers and other cooling devices. Nucleate boiling near the critical heat flux (CHF) can transport very large thermal loads with a much smaller device and much lower pumping power than for single-phase heat exchangers. However, boiling performance sharply deteriorates in a reduced-gravity environment, and operation in the CHF regime is somewhat perilous because of the risk of burnout to the device surface. New materials called microconfigured metal-graphite composites can enhance boiling. The photomicrograph shows the microconfiguration (x3000) of the copper-graphite (Cu-Gr) surface as viewed by scanning electronic microscope. The graphite fiber tips appear as plateaus with rugged surfaces embedded in the copper matrix. It has been experimentally demonstrated that this type of material manifests excellent boiling heat transfer performance characteristics and an increased CHF. Nonisothermal surfaces were less sensitive to variations of wall superheat in the CHF regime. Because of the great difference in conductivity between the copper base and the graphite fiber, the composite surfaces have a nonisothermal surface characteristic and, therefore, will have a much larger "safe" operating region in the CHF regime. In addition, the thermocapillary forces induced by the temperature differences between the fiber tips and the metal matrix play an important role in bubble detachment, and may not be adversely affected in a reduced-gravity environment. All these factors indicate that microconfigured composites may improve the reliability and economy (dominant factors in all space applications) of various thermal components found on spacecraft during future missions.

Chao, David F.↗

NASA NTRS2000

Item Description: ISS TransHab Restraint Sample and Photo Documentation

The yellow strap seen in the display is a piece of the main restraint layer of a test article for the ISS TransHab spacecraft, First conceived as a technology which is capable of supporting a [human] crew of six on an extended space journey such as the six-month trip to Mars, TransHab (short for "Transit habitat") is the first space inflatable module ever designed. As this text is written it is being considered as a replacement for the Habitation module on the International Space Station (ISS). It constitutes a major breakthrough both in technology and in tectonics: capable of tight packaging at light weight for efficient launch, the vehicle can then be inflated to its full size on orbit via its own inflation tanks. This is made possible by the separation of its main structural elements from its pressure-shell. In other words, all spacecraft flown to date have been of an exoskeletal type---i.e., its hard outer shell acts both as a pressure container and as its main channel for structural loading This includes the ISS, which is currently under construction in Low Earth Orbit [275 miles above the Earth]. By contrast TransHab is the first endoskeletal space Habitat, consisting of a dual system: a light, reconfigurable central structure of graphite composite and a multilayered, deployable pressure shell.

Adams, Constance↗

NASA NTRS1980

Integrated application of active controls (IAAC) technology to an advanced subsonic transport project. Conventional baseline configuration study

Characteristics of the U.S. domestic fleet were evaluated to determine the mission characteristics that would have the most impact on U. S. transport fuel use in the future. This resulted in selection of a 197-passenger (plus cargo), about 3710-km (2000 nmi) mission. The existing data base was reviewed and additional analysis was conducted as necessary to complete the technical descriptions. The resulting baseline configuration utilizes a double-lobe, but nearly circular, body with seven-abreast seating. External characteristics feature an 8.71 aspect ratio, 31.5-degree sweep wing, a T-tail empennage, and a dual CF6-6D2, wing-mounted engine arrangement. It provides for 22 LD-2 or 11 LD-3 containers plus bulk cargo in the lower lobe. Passenger/cargo loading, servicing provisions, taxi/takeoff speeds, and field length characteristics are all compatible with accepted airline operations and regulatory provisions. The baseline configuration construction uses conventional aluminum structure except for advanced aluminum alloys and a limited amount of graphite epoxy secondary structure. Modern systems are used, including advanced guidance, navigation, and controls which emphasize application of digital electronics and advanced displays.

Source record↗

NASA NTRS1994

NASA/CARES dual-use ceramic technology spinoff applications

NASA has developed software that enables American industry to establish the reliability and life of ceramic structures in a wide variety of 21st Century applications. Designing ceramic components to survive at higher temperatures than the capability of most metals and in severe loading environments involves the disciplines of statistics and fracture mechanics. Successful application of advanced ceramics material properties and the use of a probabilistic brittle material design methodology. The NASA program, known as CARES (Ceramics Analysis and Reliability Evaluation of Structures), is a comprehensive general purpose design tool that predicts the probability of failure of a ceramic component as a function of its time in service. The latest version of this software, CARESALIFE, is coupled to several commercially available finite element analysis programs (ANSYS, MSC/NASTRAN, ABAQUS, COSMOS/N4, MARC), resulting in an advanced integrated design tool which is adapted to the computing environment of the user. The NASA-developed CARES software has been successfully used by industrial, government, and academic organizations to design and optimize ceramic components for many demanding applications. Industrial sectors impacted by this program include aerospace, automotive, electronic, medical, and energy applications. Dual-use applications include engine components, graphite and ceramic high temperature valves, TV picture tubes, ceramic bearings, electronic chips, glass building panels, infrared windows, radiant heater tubes, heat exchangers, and artificial hips, knee caps, and teeth.

Powers, Lynn M.↗

NASA NTRS2011

Development of Passive Fuel Cell Thermal Management Technology

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA exploration program. The passive thermal management system relies on heat conduction within the cooling plate to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack rather than using a pumped loop cooling system to convectively remove the heat. Using the passive approach eliminates the need for a coolant pump and other cooling loop components which reduces fuel cell system mass and improves overall system reliability. Previous analysis had identified that low density, ultra-high thermal conductivity materials would be needed for the cooling plates in order to achieve the desired reductions in mass and the highly uniform thermal heat sink for each cell within a fuel cell stack. A pyrolytic graphite material was identified and fabricated into a thin plate using different methods. Also a development project with Thermacore, Inc. resulted in a planar heat pipe. Thermal conductivity tests were done using these materials. The results indicated that lightweight passive fuel cell cooling is feasible.

Burke, Kenneth A.↗

NASA NTRS2019

Completion of the Long Duration Wear Test of the NASA HERMeS Hall Thruster

The NASA Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5-kW Hall thruster has been the subject of extensive technology maturation by NASA GRC and JPL in preparation for development into a flight propulsion system. As part of this effort, a series of wear tests have been conducted to identify erosion phenomena and the accompanying failure modes as well as to validate service-life models for magnetically-shielded thrusters. This work presents a summary of the results obtained during the Long Duration Wear Test (LDWT), which was the third in this wear test series. The LDWT accumulated approximately 3,570 hours of operation and had the overall goal to identify and correct design or facility issues prior to the flight qualification campaign. Thruster performance, stability, and plume properties were invariant throughout the duration of the LDWT and consistent with measurements acquired during previous HERMeS performance and wear characterizations. Average erosion rates of a carbon-carbon composite pole cover were found to match those measured with graphite to within the empirical uncertainty while the previously observed time-dependence of pole cover erosion rates was linked to changes in pole cover roughness. Azimuthal variations in keeper wear rate were observed including deposition on one of the azimuthal-facing sides of the keeper mask. This strongly suggests the presence of an azimuthal component in the process driving keeper erosion.

Frieman, Jason D.↗

NASA NTRS2019

Completion of the Long Duration Wear Test of the NASA HERMeS Hall Thruster

The NASA Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5-kW Hall thruster has been the subject of extensive technology maturation by NASA GRC and JPL in preparation for development into a flight propulsion system. As part of this effort, a series of wear tests have been conducted to identify erosion phenomena and the accompanying failure modes as well as to validate service-life models for magnetically-shielded thrusters. This work presents a summary of the results obtained during the Long Duration Wear Test (LDWT), which was the third in this wear test series. The LDWT accumulated approximately 3,570 hours of operation and had the overall goal to identify and correct design or facility issues prior to the flight qualification campaign. Thruster performance, stability, and plume properties were invariant throughout the duration of the LDWT and consistent with measurements acquired during previous HERMeS performance and wear characterizations. Average erosion rates of a carbon-carbon composite pole cover were found to match those measured with graphite to within the empirical uncertainty while the previously observed time-dependence of pole cover erosion rates was linked to changes in pole cover roughness. Azimuthal variations in keeper wear rate were observed including deposition on one of the azimuthal-facing sides of the keeper mask. This strongly suggests the presence of an azimuthal component in the process driving keeper erosion.

Frieman, Jason D.↗

NASA NTRS2019

Completion of the Long Duration Wear Test of the NASA HERMeS Hall Thruster

The NASA Hall Effect Rocket with Magnetic Shielding (HERMeS) 12.5-kW Hall thruster has been the subject of extensive technology maturation by NASA GRC and JPL in preparation for development into a flight propulsion system. As part of this effort, a series of wear tests have been conducted to identify erosion phenomena and the accompanying failure modes as well as to validate service-life models for magnetically-shielded thrusters. This work presents a summary of the results obtained during the Long Duration Wear Test (LDWT), which was the third in this wear test series. The LDWT accumulated approximately 3,570 hours of operation and had the overall goal to identify and correct design or facility issues prior to the flight qualification campaign. Thruster performance, stability, and plume properties were invariant throughout the duration of the LDWT and consistent with measurements acquired during previous HERMeS performance and wear characterizations. Average erosion rates of a carbon-carbon composite pole cover were found to match those measured with graphite to within the empirical uncertainty while the previously observed time-dependence of pole cover erosion rates was linked to changes in pole cover roughness. Azimuthal variations in keeper wear rate were observed including deposition on one of the azimuthal-facing sides of the keeper mask. This strongly suggests the presence of an azimuthal component in the process driving keeper erosion.

Jason David Frieman↗

NASA NTRS2004

Nanotube Activities at NASA-Johnson Space Center

Nanotube activities at NASA-Johnson Space Center include production, purification, characterization as well as applications of single wall carbon nanotubes (SWCNTs). A parametric study of the pulsed laser ablation process is recently completed to monitor the effect of production parameters including temperature, buffer gas, flow rate, pressure, and laser fluence. Enhancement of production is achieved by rastering the graphite target and by increasing the target surface temperature with a cw laser. In-situ diagnostics during production included time resolved passive emission and laser induced fluorescence from the plume. The improvement of the purity by a variety of steps in the purification process is monitored by characterization techniques including SEM, TEM, Raman, UV-VIS-NIR and TGA. A recently established NASA-JSC protocol for SWCNT characterization is undergoing revision with feedback from nanotube community. Efforts at JSC over the past five years in composites have centered on structural polymer/nanotube systems. Recent activities broadened this focus to multifunctional materials, supercapacitors, fuel cells, regenerable CO2 absorbers, electromagnetic shielding, radiation dosimetry and thermal management systems of interest for human space flight. Preliminary tests indicate improvement of performance in most of these applications because of the large Surface area as well as high electrical and thermal conductivity exhibited by SWCNTs. Comparison with existing technologies and possible future improvements in the SWCNT materials sill be presented.

Arepalli, Sivaram↗

NASA NTRS1993

Precision linear shaped charge severance of graphite-epoxy materials

This paper presents Precision Linear Shaped Charge (PLSC) components designed to sever a variety of target materials. Recent data for the severance of graphite-epoxy panels or targets with PLSC's are presented. A brief history of the requirement to originate the development of PLSC's for weapon components at Sandia National Laboratories is presented. The Department of Energy's (DOE) nuclear weapon systems have continually decreased in size. Today's relatively small weapons require the design of much more efficient, lighter, and smaller explosive components because fragments, air shocks, and pyro-shocks associated with the function of these components can damage electrical and other sensitive components located nearby. The DOE requirements for PLSC's are listed. Therefore, linear shaped charge (LSC) components for weapon systems can no longer be empirically or experimentally designed for a given application. Many of today's designs require severing concentric cylinders, for example, where the LSC jet is designed to sever only one of the two cylinders as was the case for the B90/Nuclear Depth Strike Bomb. Therefore, code modeling and simulation technology must be utilized to obtain a better understanding of the LSC jet hydrodynamic penetration, fracture, shear, and spall mechanisms associated with the severance of metallic as well as composite targets.

Vigil, Manuel G.↗

NASA NTRS2004

Enhanced Boiling on Micro-Configured Composite Surfaces Under Microgravity Conditions

Two experimental setups: High Heat Flux Pool Boiling Setup and Optical system of Measuring Contact Angle and Spreading Parameters were established and a series of experiments was conducted. The experimental work on the nucleate boiling performance of both Freon-113 and water on the composite surfaces has been finished and the results show that the composite surface with 25% volume fraction of graphite fibers in the copper matrix has the best enhancing performance. Stronger enhancement was obtained for water compared to Freon-113. The wall superheat initiating boiling was reduced 40% and 35% and the heat flux of the nucleate boiling was augmented up to ten times and 6.7 times, respectively. A bubble departure model has been presented to explain the enhancement mechanism of the boiling heat transfer on the composite surfaces. A powerful optical method to measure contact angle and spreading parameters of liquids on solid surfaces, including both transparent and non-transparent substrates, has been developed and successfully used in the measurements for various liquid-solid systems. The experimental work on identification of profiles near three-phase line by laser shadowgraphy method has been finished and the characteristics of the three-phase line for different liquid-solid systems were unveiled, which is very important to understand the mechanism of boiling under microgravity conditions. The four basic patterns of sessile profile were discovered through caustics and caustic-diffraction analysis by applying wave theory in shadowgraphy technology, which contributes to clearly explain the different characteristics of wetting and spreading of various liquids on a solid surface, and therefore to further understand the bubble departure mechanisms. A new working pattern of heat pipes using working fluids with positive surface-tension gradient against temperature was discovered and analyzed, and then the new heat pipe systems using this kind of working fluids have been presented. Two patent devices, i.e. Shadowgraphic Method to Measure Properties of Sessile Drops and Heat Pipe Systems Using New Working Fluids, have been developed; the former has been approved by The United States Patent & Trademark Office and the latter is being examined.

Source record↗

NASA NTRSDate not supplied

High-Enthalpy Testing to Validate Simulation of an Aerosol Capture Probe

AERACEPT (Aerosol Rapid Analysis Combined Entry Probe/sonde Technology) is a developing technology enabling in-situ aerosol particle sampling and analysis in a small spacecraft mission envelope. It integrates a passive aerosol sample collection system into a probe’s thermal protection system (TPS) to remove the need for heat shield separation and active descent control (parachutes, gliders, etc.). AERACEPT is being validated against the requirements of the Nephele mission concept, which targets the middle and lower Venus cloud layers. The proposed technology employs 3D Carbon-Carbon (3D-CC) at the probe’s nose to withstand the extreme environments encountered in a Venus entry without producing pyrolysis gases that would contaminate the mission sample collection. Any shape change of this 3D-CC sample inlet will affect airflow through the sampling system, thereby impacting aerosol sample collection bias and efficiency. Accurate prediction of the nose’s material response during entry is there-fore of fundamental importance to the development and practical use of this technology. As a result, the AERACEPT project is planning a test campaign in the newly built PlasmatronX facility with a novel “Open Iso-Q” test article to validate state-of-the-art material response tools for a simulated Venus entry. The PlasmatronX is a 350 kW inductively-coupled plasma facility developed and run by the Center for Hypersonics and Entry Systems Studies at the University of Illinois at Urbana-Champaign. The facility can support ground testing for a variety of planetary destinations by simulating entry conditions in Nitrogen, Air, and Carbon Dioxide. To best simulate the Venus atmosphere and match flight-like recession, the planned AERACEPT test campaign will use Carbon Dioxide as its test gas. AERACEPT has designed two test articles for this campaign: 1) a standard test article whose curved surface approximates a constant applied heat flux (“Closed Iso-Q” model) and 2) a novel inlet test article with a through-hole at the stagnation point (“Open Iso-Q” model). Both article types consist of a 3D-CC sample bonded to a graphite fixture. All articles will be laser scanned before and after testing to estimate shape change and recession, and the “Closed Iso-Q” articles will be instrumented with thermocouples to provide temperature histories. The test article temperatures and inlet shape change will be compared against simulations run with the Porous material Analysis Toolbox based on OpenFOAM (PATO) to validate the AERACEPT 3D-CC material response model. Due to the high thermal conductivity of 3D-CC, multidimensional effects have a large influence on the test article temperature and the standard 1-D material response tools are not sufficient for test planning. The test campaign features (e.g. article design, run duration, heat fluxes) are therefore informed by a series of 3-D simulations using state-of-the-art material response tools such as PATO. The test campaign is scheduled for spring of 2024. Expected results include 1) Key drivers of selected test conditions (e.g. matching mission flight atmosphere & recession), 2) Simulation results that informed test article design, 3) Acquired test data such as recession measurements, temperature histories, and photos, and 4) Comparisons between test results and simulation predictions.

AERACEPT↗

NASA NTRSDate not supplied

High-Enthalpy Testing to Validate Simulation of an Aerosol Capture Probe

AERACEPT (Aerosol Rapid Analysis Combined Entry Probe/sonde Technology) is a developing technology enabling in-situ aerosol particle sampling and analysis in a small spacecraft mission envelope. It integrates a passive aerosol sample collection system into a probe’s thermal protection system (TPS) to remove the need for heat shield separation and active descent control (parachutes, gliders, etc.). AERACEPT is being validated against the requirements of the Nephele mission concept, which targets the middle and lower Venus cloud layers. The proposed technology employs 3D Carbon-Carbon (3D-CC) at the probe’s nose to withstand the extreme environments encountered in a Venus entry without producing pyrolysis gases that would contaminate the mission sample collection. Any shape change of this 3D-CC sample inlet will affect airflow through the sampling system, thereby impacting aerosol sample collection bias and efficiency. Accurate prediction of the nose’s material response during entry is there-fore of fundamental importance to the development and practical use of this technology. As a result, the AERACEPT project is planning a test campaign in the newly built PlasmatronX facility with a novel “Open Iso-Q” test article to validate state-of-the-art material response tools for a simulated Venus entry. The PlasmatronX is a 350 kW inductively-coupled plasma facility developed and run by the Center for Hypersonics and Entry Systems Studies at the University of Illinois at Urbana-Champaign. The facility can support ground testing for a variety of planetary destinations by simulating entry conditions in Nitrogen, Air, and Carbon Dioxide. To best simulate the Venus atmosphere and match flight-like recession, the planned AERACEPT test campaign will use Carbon Dioxide as its test gas. AERACEPT has designed two test articles for this campaign: 1) a standard test article whose curved surface approximates a constant applied heat flux (“Closed Iso-Q” model) and 2) a novel inlet test article with a through-hole at the stagnation point (“Open Iso-Q” model). Both article types consist of a 3D-CC sample bonded to a graphite fixture. All articles will be laser scanned before and after testing to estimate shape change and recession, and the “Closed Iso-Q” articles will be instrumented with thermocouples to provide temperature histories. The test article temperatures and inlet shape change will be compared against simulations run with the Porous material Analysis Toolbox based on OpenFOAM (PATO) to validate the AERACEPT 3D-CC material response model. Due to the high thermal conductivity of 3D-CC, multidimensional effects have a large influence on the test article temperature and the standard 1-D material response tools are not sufficient for test planning. The test campaign features (e.g. article design, run duration, heat fluxes) are therefore informed by a series of 3-D simulations using state-of-the-art material response tools such as PATO. The test campaign is scheduled for spring of 2024. Expected results include 1) Key drivers of selected test conditions (e.g. matching mission flight atmosphere & recession), 2) Simulation results that informed test article design, 3) Acquired test data such as recession measurements, temperature histories, and photos, and 4) Comparisons between test results and simulation predictions.

AERACEPT↗

NASA NTRS1991

Planetary engineering

Assuming commercial fusion power, heavy lift vehicles and major advances in genetic engineering, the authors survey possible late-21st century methods of working major transformations in planetary environments. Much more Earthlike climates may be produced on Mars by generating low freezing point greenhouse gases from indigenous materials; on Venus by biological conversion of CO2 to graphite, by canceling the greenhouse effect with high-altitude absorbing fine particles, or by a sunshield at the first Lagrangian point; and on Titan by greenhouses and/or fusion warming. However, in our present state of ignorance we cannot guarantee a stable endstate or exclude unanticipated climatic feedbacks or other unintended consequences. Moreover, as the authors illustrate by several examples, many conceivable modes of planetary engineering are so wasteful of scarce solar system resources and so destructive of important scientific information as to raise profound ethical issues, even if they were economically feasible, which they are not. Global warming on Earth may lead to calls for mitigation by planetary engineering, e.g., emplacement and replenishment of anti-greenhouse layers at high altitudes, or sunshields in space. But here especially we must be concerned about precision, stability, and inadvertent side-effects. The safest and most cost-effective means of countering global warming - beyond, e.g., improved energy efficiency, CFC bans and alternative energy sources - is the continuing reforestation of approximately 2 times 107 sq km of the Earth's surface. This can be accomplished with present technology and probably at the least cost.

Pollack, James B.↗

NASA NTRS2003

Molecular modeling of polymer composite-analyte interactions in electronic nose sensors

We report a molecular modeling study to investigate the polymer-carbon black (CB) composite-analyte interactions in resistive sensors. These sensors comprise the JPL electronic nose (ENose) sensing array developed for monitoring breathing air in human habitats. The polymer in the composite is modeled based on its stereoisomerism and sequence isomerism, while the CB is modeled as uncharged naphthalene rings with no hydrogens. The Dreiding 2.21 force field is used for the polymer, solvent molecules and graphite parameters are assigned to the carbon black atoms. A combination of molecular mechanics (MM) and molecular dynamics (NPT-MD and NVT-MD) techniques are used to obtain the equilibrium composite structure by inserting naphthalene rings in the polymer matrix. Polymers considered for this work include poly(4-vinylphenol), polyethylene oxide, and ethyl cellulose. Analytes studied are representative of both inorganic and organic compounds. The results are analyzed for the composite microstructure by calculating the radial distribution profiles as well as for the sensor response by predicting the interaction energies of the analytes with the composites. c2003 Elsevier Science B.V. All rights reserved.

NASA Center JPL↗

NASA NTRS1995

An Accelerated Development, Reduced Cost Approach to Lunar/Mars Exploration Using a Modular NTR-Based Space Transportation System

The results of integrated systems and mission studies are presented which quantify the benefits and rationale for developing a common, modular lunar/Mars space transportation system (STS) based on nuclear thermal rocket (NTR) technology. At present NASA's Exploration Program Office (ExPO) is considering chemical propulsion for an 'early return to the Moon' and NTR propulsion for the more demanding Mars missions to follow. The time and cost to develop these multiple systems are expected to be significant. The Nuclear Propulsion Office (NPO) has examined a variety of lunar and Mars missions and heavy lift launch vehicle (HLLV) options in an effort to determine a 'standardized' set of engine and stage components capable of satisfying a wide range of Space Exploration Initiative (SEI) missions. By using these components in a 'building block' fashion, a variety of single and multi-engine lunar and Mars vehicles can be configured. For NASA's 'First Lunar Outpost' (FLO) mission, an expendable NTR stage powered by two 50 klbf engines can deliver approximately 96 metric tons (t) to translunar injection (TLI) conditions for an initial mass in low earth orbit (IMLEO) of approximately 198 t compared to 250 t for a cryogenic chemical TLI stage. The NTR stage liquid hydrogen (LH2) tank has a 10 m diameter, 14.5 m length, and 66 t LH2 capacity. The NTR utilizes a UC-ZrC-graphite 'composite' fuel with a specific impulse (Isp) capability of approximately 900 s and an engine thrust-to-weight ratio of approximately 4.3. By extending the size and LH2 capacity of the lunar NTR stage to approximately 20 m and 96 t, respectively, a single launch Mars cargo vehicle capable of delivering approximately 50 t of surface payload is possible. Three 50 klbf NTR engines and the two standardized LH2 tank sizes developed for lunar and Mars cargo vehicle applications would be used to configure the Mars piloted vehicle for a mission as early as 2010. The paper describes the features of the 'common' NTR-based moon/Mars STS, examines performance sensitivities resulting from different 'mission mode' assumptions, and quantifies potential schedule and cost benefits resulting from this modular moon/Mars NTR vehicle approach.

Borowski, S.↗

NASA NTRSDate not supplied

Development of New Lunar Highland Regolith Simulant, NUW-LHT-5M

Introduction: NASA has a need for large quantities of lunar simulants that closely match future manned lunar missions at landing sites near the Lunar South Pole. The current simulant was designed to approximate NU-LHT-2M, and -4M, except using natural minerals and a fully synthetic, non-basaltic, high calcium glass. Washington Mills in Niagara Falls, NY was contracted to produce this new simulant due to their electric arc furnace (EAF) fusion technology and capabilities for crushing and sizing ceramics. The primary objectives of this work were: (1) to create a commercially produced simulant that contains a high fidelity, high calcium (An90+), low Mg/Fe glass without basaltic constituents; (2) to create a simulant that uses existing, terrestrially mined, and readily available minerals blended with a synthetic glass, and (3) accomplish objectives (1) and (2) using conventional processing methods capable of production levels that can meet substantial current and future demands of NASA projects. Another consideration was that highland simulants closest to meeting these requirements, NU-LHT-2M and -4M types, are out of production and largely out of stock. Design: The design chosen for development and production for this work is NU-LHT-2M, de-signed by Doug Stoeser and Douglas Rickman, which uses Stillwater anorthosite and norite rocks and synthetic glass. The composition targeted the average composition, glass content and particle size distribution of Apollo 16 samples [1]. The design utilizes two Stillwater minerals, anorthosite (37.7 wt.%), norite (17.6 wt.%), a commercially sourced olivine (4.7 wt.%), and a synthetic glass (40 wt.%). Processing: Stillwater rocks were hand collected and initially crushed by the USGS. Further crushing and milling was performed at Washing-ton Mills. For the glass, oxides were blended in the ap-propriate ratios, blended in a v-blender, and placed in a graphite lined, water cooled pot. The mixture was fused in Washington Mills’ pilot scale, 500 kW EAF. The molten glass was then poured into water and quenched to inhibit crystallization. Several pour/quench cycles were required to produce the total quantity of glass needed. Anorthosite, norite and olivine were milled together to the target particle size in a ball mill. The glass was ball milled separately. The complete simulant was produced by blending the milled materials. Particle size distribution, phase and chemical analyses of the materials was were per-formed at Washington Mills. Results: The glass composition was found to match the Apollo 16 oxide content average [1] quite well, with the exception of SiO2 and Fe2O3. The deviation of SiO2 and Fe2O3 from batched content was believed to be due to limitations inherent in the use of the arc furnace technique for these types of materials. A particle size distribution of the full simulant formulation closely matching the average for the Apollo 16 samples was also achieved. Fig. 1 shows the morphology of the final simulant particles. The size distribution is compared to the target in Fig. 2. Conclusions: A new lunar highlands type simulant containing a high-quality synthetic glass, closely matching an average composition of the Apollo 16 regolith was produced. Processing utilized easily scalable mineral and glass making methods.

simulant↗

NASA NTRS2005

NSTAR Extended Life Test Discharge Chamber Flake Analysis

The Extended Life Test (ELT) of the NASA Solar Electric Propulsion Technology Readiness (NSTAR) ion thruster was concluded after 30,352 hours of operation. The ELT was conducted using the Deep Space 1 (DS1) back-up flight engine, a 30 cm diameter xenon ion thruster. Post-test inspection of the ELT engine revealed numerous contaminant flakes distributed over the bottom of the cylindrical section of the anode within the discharge chamber (DC). Extensive analyses were conducted to determine the source of the particles, which is critical to the understanding of degradation mechanisms of long life ion thruster operation. Analyses included: optical microscopy (OM) and particle length histograms, field emission scanning electron microscopy (FESEM) combined with energy dispersive spectroscopy (EDS), and atomic oxygen plasma exposure tests. Analyses of the particles indicate that the majority of the DC flakes consist of a layered structure, typically with either two or three layers. The flakes comprising two layers were typically found to have a molybdenum-rich (Mo-rich) layer on one side and a carbon-rich (C-rich) layer on the other side. The flakes comprising three layers were found to be sandwich-like structures with Mo-rich exterior layers and a C-rich interior layer. The presence of the C-rich layers indicates that these particles were produced by sputter deposition build-up on a surface external to the discharge chamber from ion sputter erosion of the graphite target in the test chamber. This contaminant layer became thick enough that particles spalled off, and then were electro-statically attracted into the ion thruster interior, where they were coated with Mo from internal sputter erosion of the screen grid and cathode components. Atomic oxygen tests provided evidence that the DC chamber flakes are composed of a significant fraction of carbon. Particle size histograms further indicated that the source of the particles was spalling of carbon flakes from downstream surfaces. Analyses of flakes taken from the downstream surface of the accelerator grid provided additional supportive information. The production of the downstream carbon flakes, and hence the potential problems associated with the flake particles in the ELT ion thruster engine is a facility induced effect and would not occur in the space environment.

deGroh, Kim K.↗