SEARCH · Engineering Papers

Results for “Material test reactors”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

225 records · Page 13

All sources NASA NTRS DOE OSTI

NASA NTRS2024

Reliable and Efficient Electrochemical Recovery of O 2 from Metabolic CO 2 at the International Space Station (ISS)

Maximum O 2 recovery from metabolic carbon dioxide (CO 2 ) is desired for future long-duration missions beyond Low Earth Orbit (LEO). The O 2 recovery for the Environmental Control and Life Support System (ECLSS) at the International Space Station (ISS), presently limited to 50% (Sabatier), must be highly reliable and efficient and recover a minimum of 75% oxygen (O 2 ) from metabolic CO 2 . An alternative technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) via a Microfluidic Electrochemical Reactor (MFECR) approach has the potential to increase O 2 recovery significantly and reduce the complexity of the ECLSS O 2 recovery at the ISS as it would replace three pieces, the CO 2 Reduction Assembly (CRA) (Sabatier reactor), the Oxygen Generation Assembly (OGA), and the Plasma Pyrolysis Assembly (PPA). The MFECR's electrochemical process generates ethylene (C 2 H 4 ) and carbon moxide (CO) instead of methane (CH 4 ) (Sabatier) as a byproduct, eliminating the need for further dehydrogenation through the PPA. As in the OGA, the MFECR's electrochemical process generates O 2 and hydrogen (H 2 ) from the water electrolysis process. MSFC and the University of Texas in Arlington (UTA) have jointly designed and fabricated an MFECR's single cell that operates at ambient conditions and utilizes a proprietary catalysis highly selective on reducing CO 2 to C 2 H 4 and CO at the cathode. This MFECR's single cell consists of gas diffusion layers at the cathode and anode for respective intake of CO 2 and output of O 2 from the catalytic layer. This approach is expected to substantially improve the ISS ECLSS sustainability and reduce power and weight requirements as the MFECR would replace three units currently installed in the ISS. In this paper, the authors discuss the outcome of preliminary tests, the current development, and the evaluation efforts on different alternatives for the cathode and the anode configurations, the setup of the MFECR at an engineering development unit (EDU) scale, and the O 2 recovery performance, and evaluation efforts on different alternatives on not only the configuration and setup of the MFECR at an Engineering Design Unit (EDU) scale but also the selection of component materials.

Jesus A Dominguez↗

NASA NTRS2015

Initial Operation of the Nuclear Thermal Rocket Element Environmental Simulator

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) facility is designed to perform realistic non-nuclear testing of nuclear thermal rocket (NTR) fuel elements and fuel materials. Although the NTREES facility cannot mimic the neutron and gamma environment of an operating NTR, it can simulate the thermal hydraulic environment within an NTR fuel element to provide critical information on material performance and compatibility. The NTREES facility has recently been upgraded such that the power capabilities of the facility have been increased significantly. At its present 1.2 MW power level, more prototypical fuel element temperatures nay now be reached. The new 1.2 MW induction heater consists of three physical units consisting of a transformer, rectifier, and inverter. This multiunit arrangement facilitated increasing the flexibility of the induction heater by more easily allowing variable frequency operation. Frequency ranges between 20 and 60 kHz can accommodated in the new induction heater allowing more representative power distributions to be generated within the test elements. The water cooling system was also upgraded to so as to be capable of removing 100% of the heat generated during testing In this new higher power configuration, NTREES will be capable of testing fuel elements and fuel materials at near-prototypic power densities. As checkout testing progressed and as higher power levels were achieved, several design deficiencies were discovered and fixed. Most of these design deficiencies were related to stray RF energy causing various components to encounter unexpected heating. Copper shielding around these components largely eliminated these problems. Other problems encountered involved unexpected movement in the coil due to electromagnetic forces and electrical arcing between the coil and a dummy test article. The coil movement and arcing which were encountered during the checkout testing effectively destroyed the induction coil in use at the time and resulted in NTREES being out of commission for a couple of months while a new stronger coil was procured. The new coil includes several additional pieces of support structure to prevent coil movement in the future. In addition, new insulating test article support components have been fabricated to prevent unexpected arcing to the test articles. Additional activities are also now underway to address ways in which the radial temperature profiles across test articles may be controlled such that they are more prototypical of what they would encounter in an operating nuclear engine. The causes of the temperature distribution problem are twofold. First, the fuel element test article is isolated in NTREES as opposed to being in the midst of many other mostly identical fuel elements in a nuclear engine. As a result, the fuel element heat flux boundary conditions in NTREES are far from adiabatic as would normally be the case in a reactor. Second, induction heating skews the power distribution such that power is preferentially deposited near the outside of the fuel element. Nuclear heating, conversely, deposits its power much more uniformly throughout the fuel element. Current studies are now looking at various schemes to adjust the amount of thermal radiation emitted from the fuel element surface so as to essentially vary the thermal boundary conditions on the test article. It is hoped that by properly adjusting the thermal boundary conditions on the fuel element test article, it may be possible to substantially correct for the inappropriate radial power distributions resulting from the induction heating so as to yield a more nearly correct temperature distribution throughout the fuel element.

Emrich, William J., Jr.↗

NASA NTRS2012

Curved Waveguide Based Nuclear Fission for Small, Lightweight Reactors

The focus of the presented work is on the creation of a system of grazing incidence, supermirror waveguides for the capture and reuse of fission sourced neutrons. Within research reactors, neutron guides are a well known tool for directing neutrons from the confined and hazardous central core to a more accessible testing or measurement location. Typical neutron guides have rectangular, hollow cross sections, which are crafted as thin, mirrored waveguides plated with metal (commonly nickel). Under glancing angles with incoming neutrons, these waveguides can achieve nearly lossless transport of neutrons to distant instruments. Furthermore, recent developments have created supermirror surfaces which can accommodate neutron grazing angles up to four times as steep as nickel. A completed system will form an enclosing ring or spherical resonator system to a coupled neutron source for the purpose of capturing and reusing free neutrons to sustain and/or accelerate fission. While grazing incidence mirrors are a known method of directing and safely using neutrons, no method has been disclosed for capture and reuse of neutrons or sustainment of fission using a circular waveguide structure. The presented work is in the process of fabricating a functional, highly curved, neutron supermirror using known methods of Ni-Ti layering capable of achieving incident reflection angles up to four times steeper than nickel alone. Parallel work is analytically investigating future geometries, mirror compositions, and sources for enabling sustained fission with applicability to the propulsion and energy goals of NASA and other agencies. Should research into this concept prove feasible, it would lead to development of a high energy density, low mass power source potentially capable of sustaining fission with a fraction of the standard critical mass for a given material and a broadening of feasible materials due to reduced rates of release, absorption, and non-fission for neutrons. This advance could be applied to direct propulsion through guided fission products or as a secondary energy source for high impulse electric propulsion. It would help meet national needs for highly efficient energy sources with limited dependence on fossil fuels or conflict materials, and it would improve the use of low grade fissile materials which would help reduce national stockpiles and waste.

Coker, Robert↗

NASA NTRS2015

Optimization of a Wcl6 CVD System to Coat UO2 Powder with Tungsten

In order to achieve deep space exploration via Nuclear Thermal Propulsion (NTP), Marshall Space Flight Center (MSFC) is developing W-UO2 CERMET fuel elements, with focus on fabrication, testing, and process optimization. A risk of fuel loss is present due to the CTE mismatch between tungsten and UO2 in the W-60vol%UO2 fuel element, leading to high thermal stresses. This fuel loss can be reduced by coating the spherical UO2 particles with tungsten via H2/WCl6 reduction in a fluidized bed CVD system. Since the latest incarnation of the inverted reactor was completed, various minor modifications to the system design were completed, including an inverted frit sublimer. In order to optimize the parameters to achieve the desired tungsten coating thickness, a number of trials using surrogate HfO2 powder were performed. The furnace temperature was varied between 930 C and 1000degC, and the sublimer temperature was varied between 140 C and 200 C. Each trial lasted 73-82 minutes, with one lasting 205 minutes. A total of 13 trials were performed over the course of three months, two of which were re-coatings of previous trials. The powder samples were weighed before and after coating to roughly determine mass gain, and Scanning Electron Microscope (SEM) data was also obtained. Initial mass results indicated that the rate of layer deposition was lower than desired in all of the trials. SEM confirmed that while a uniform coating was obtained, the average coating thickness was 9.1% of the goal. The two re-coating trials did increase the thickness of the tungsten layer, but only to an average 14.3% of the goal. Therefore, the number of CVD runs required to fully coat one batch of material with the current configuration is not feasible for high production rates. Therefore, the system will be modified to operate with a negative pressure environment. This will allow for better gas mixing and more efficient heating of the substrate material, yielding greater tungsten coating per trial.

Belancik, Grace A.↗

NASA NTRS2015

Lightweight Damage Tolerant, High-Temperature Radiators for Nuclear Power and Propulsion

NASA is increasingly emphasizing exploration to bodies beyond near-Earth orbit. New propulsion systems and new spacecraft are being built for these missions. As the target bodies get further out from Earth, high energy density systems, e.g., nuclear fusion, for propulsion and power will be advantageous. The mass and size of these systems, including supporting systems such as the heat exchange system, including thermal radiators, will need to be as small as possible. Conventional heat exchange systems are a significant portion of the total thermal management mass and size. Nuclear electric propulsion (NEP) is a promising option for high-speed, in-space travel due to the high energy density of nuclear fission power sources and efficient electric thrusters. Heat from the reactor is converted to power for use in propulsion or for system power. The heat not used in the power conversion is then radiated to space as shown in figure 1. Advanced power conversion technologies will require high operating temperatures and would benefit from lightweight radiator materials. Radiator performance dictates power output for nuclear electric propulsion systems. Pitch-based carbon fiber materials have the potential to offer significant improvements in operating temperature, thermal conductivity, and mass. These properties combine to allow significant decreases in the total mass of the radiators and significant increases in the operating temperature of the fins. A Center-funded project at NASA Marshall Space Flight Center has shown that high thermal conductivity, woven carbon fiber fins with no matrix material, can be used to dissipate waste heat from NEP systems and because of high specific power (kW/kg), will require less mass and possibly less total area than standard metal and composite radiator fins for radiating the same amount of heat. This project uses an innovative approach to reduce the mass and size required for the thermal radiators to the point that in-space NEP and power is enabled. High thermal conductivity carbon fibers are lightweight, damage tolerant, and can be heated to high temperature. Areal densities in the NASA set target range of 2 to 4 kg/m2 (for enabling NEP) are achieved and with specific powers (kW/kg) a factor of about 7 greater than conventional metal fins and about 1.5 greater than carbon composite fins. Figure 2 shows one fin under test. All tests were done under vacuum conditions.

Craven, Paul D.↗

NASA NTRS1992

Space Resources

Space resources must be used to support life on the Moon and exploration of Mars. Just as the pioneers applied the tools they brought with them to resources they found along the way rather than trying to haul all their needs over a long supply line, so too must space travelers apply their high technology tools to local resources. The pioneers refilled their water barrels at each river they forded; moonbase inhabitants may use chemical reactors to combine hydrogen brought from Earth with oxygen found in lunar soil to make their water. The pioneers sought temporary shelter under trees or in the lee of a cliff and built sod houses as their first homes on the new land; settlers of the Moon may seek out lava tubes for their shelter or cover space station modules with lunar regolith for radiation protection. The pioneers moved further west from their first settlements, using wagons they had built from local wood and pack animals they had raised; space explorers may use propellant made at a lunar base to take them on to Mars. The concept for this report was developed at a NASA-sponsored summer study in 1984. The program was held on the Scripps campus of the University of California at San Diego (UCSD), under the auspices of the American Society for Engineering Education (ASEE). It was jointly managed under the California Space Inst. and the NASA Johnson Space Center, under the direction of the Office of Aeronautics and Space Technology (OAST) at NASA Headquarters. The study participants (listed in the addendum) included a group of 18 university teachers and researchers (faculty fellows) who were present for the entire 10-week period and a larger group of attendees from universities, Government, and industry who came for a series of four 1-week workshops. The organization of this report follows that of the summer study. Space Resources consists of a brief overview and four detailed technical volumes: (1) Scenarios; (2) Energy, Power, and Transport; (3) Materials; (4) Social Concerns. Although many of the included papers got their impetus from workshop discussions, most have been written since then, thus allowing the authors to base new applications on established information and tested technology. All these papers have been updated to include the authors' current work. This overview, drafted by faculty fellow Jim Burke, describes the findings of the summer study, as participants explored the use of space resources in the development of future space activities and defined the necessary research and development that must precede the practical utilization of these resources. Space resources considered included lunar soil, oxygen derived from lunar soil, material retrieved from near-Earth asteroids, abundant sunlight, low gravity, and high vacuum. The study participants analyzed the direct use of these resources, the potential demand for products from them, the techniques for retrieving and processing space resources, the necessary infrastructure, and the economic tradeoffs. This is certainly not the first report to urge the utilization of space resources in the development of space activities. In fact, Space Resources may be seen as the third of a trilogy of NASA Special Publications reporting such ideas arising from similar studies. It has been preceded by Space Settlements: A Design Study (NASA SP-413) and Space Resources and Space Settlements (NASA SP-428). And other, contemporaneous reports have responded to the same themes. The National Commission on Space, led by Thomas Paine, in Pioneering the Space Frontier, and the NASA task force led by astronaut Sally Ride, in Leadership and America's Future in Space, also emphasize expansion of the space Infrastructure; more detailed exploration of the Moon, Mars, and asteroids; an early start on the development of the technology necessary for using space resources; and systematic development of the skills necessary for long-term human presence in space. Our report does not represent any Government-authorized view or official NASA policy. NASA's official response to these challenging opportunities must be found in the reports of its Office of Exploration, which was established in 1987. That office's report, released in November 1989, of a 90-day study of possible plans for human exploration of the Moon and Mars is NASA's response to the new initiative proposed by President Bush on July 20, 1989, the 20th anniversary of the Apollo 11 landing on the Moon: "First, for the coming decade, for the 1990s, Space Station Freedom, our critical next step in all our space endeavors. And next, for the new century, back to the Moon, back to the future, and this time, back to stay. And then a journey into tomorrow, a journey to another planet, a manned mission to Mars." This report, Space Resources, offers substantiation for NASA's bid to carry out that new initiative.

McKay, Mary Fae↗

NASA NTRS2010

Integration of In-Situ Resource Utilization Into Lunar/Mars Exploration Through Field Analogs

The NASA project to develop In-Situ Resource Utilization (ISRU) technologies, in partnership with commercial and international collaborators, has achieved full system demonstrations of oxygen production using native regolith simulants. These demonstrations included robotic extraction of material from the terrain, sealed encapsulation of material in a pressurized reactor; chemical extraction of oxygen from the material in the form of water, and the electrolysis of water into oxygen and hydrogen for storage and reuse. These successes have provided growing confidence in the prospects of ISRU oxygen production as a credible source for critical mission consumables in preparation for and during crewed missions to the moon and other destinations. Other ISRU processes, especially relevant to early lunar exploration scenarios, have also been shown to be practical, including the extraction of subsurface volatiles, especially water, and the thermal processing of surface materials for civil engineering uses and for thermal energy storage. This paper describes these recent achievements and current NASA ISRU development and demonstration activity. The ability to extract and process resources at the site of exploration into useful products such as propellants, life support and power system consumables; and radiation and rocket exhaust plume debris shielding, known as In-Situ Resource Utilization or ISRU, has the potential to significantly reduce the launch mass, risk, and cost of robotic and human exploration of space. The incorporation of ISRU into missions can also significantly influence technology selection and system development in other areas such as power, life support, and propulsion. For example. the ability to extract or produce large amounts of oxygen and/or water in-situ could minimize the need to completely close life support air and water processing system cycles, change thermal and radiation protection of habitats, and influence propellant selection for ascent vehicles and surface propulsive hoppers. While concepts and even laboratory work on evaluating and developing ISRU techniques such as oxygen extraction from lunar regolith have been going on since before the Apollo 11 Moon landing, no ISRU system has ever flown in space, and only recently have ISRU technologies been developed at a scale and at a system level that is relevant to actual robotic and human mission applications. Because ISRU hardware and systems have never been demonstrated or utilized before on robotic or human missions, architecture and mission planners and surface system hardware developers are hesitant to rely on ISRU products and services that are critical to mission and system implementation success. To build confidence in ISRU systems for future missions and assess how ISRU systems can best influence and integrate with other surface system elements, NASA, with international partners, are performing analog field tests to understand how to take advantage of ISRU capabilities and benefits with the minimum of risk associated with introducing this game-changing approach to exploration. This paper will describe and review the results of four analog field tests (Moses Lake in 6/08, Mauna Kea in 11/08. Flagstaff in 9/09; and Mauna Kea in 1/10) that have begun the process of integrating ISRU into robotic and human exploration systems and missions, and propose future ISRU-related analog field test activities that can be performed in collaboration with international space agencies.

Sanders, Gerald B.↗

NASA NTRS2015

On The Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in-situ materials will become increasingly critical. As man's presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in-situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. This is important because gamma and particle radiation constitute a serious but reducible threat to long-term survival of human beings, electronics, and other materials in space environments. Also, it is anticipated that surface structures will constitute the primary mass element of lunar or Martian launch requirements. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for self-sufficiency necessary for long-duration habitation. Previously, under the auspices of the MSFC In Situ Fabrication and Repair (ISFR) project and more recently, under the joint MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in situ resources. One such technology, known as Contour Crafting (additive construction), is shown in Figure 1, along with a typical structure fabricated using this technology. This paper will present the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using the Contour Crafting process. This process, conceived initially for rapid development of cementitious structures on Earth, also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and imported binder material or binders developed from in situ materials. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. These binder materials have resulted from extensive evaluation and include both "imported" binder materials that might be launched from Earth as well as some binder materials that can theoretically also be derived from existing regolith materials. They were chosen to 1) reduce penetrating radiation as much as possible, primarily with hydrogen-bearing polymers, 2) attempt to provide an air-tight structure, 3) sufficiently mix and adsorb to regolith grains for strength, 4) maximize tolerance to day-night thermal cycling, 5) possibly increase electrical conductivity to dissipate any accumulated static charge, and 6) ease their application on planetary surfaces (specifically, the accommodation of reduced atmosphere and lack of heat sinks). Some of these materials have been tested with respect to radiation mitigation, micrometeorite resistance, and resistance to larger, slower-traveling pieces of regolith impinging on the surface, simulating nearby launch and landing activities. Conceptual designs for a Continuous Feedstock Delivery/Mixing System (CFDMS) will also be presented and future planned activities will be discussed as well.

Werkheiser, Niki↗

NASA NTRS2017

Robust Exploration and Commercial Missions to the Moon Using NTR LANTR Propulsion and Lunar-Derived Propellants

The nuclear thermal rocket (NTR) has frequently been identified as a key space asset required for the human exploration of Mars. This proven technology can also provide the affordable access through cislunar space necessary for commercial development and sustained human presence on the Moon. In his post-Apollo Integrated Space Program Plan (1970-1990), Wernher von Braun, proposed a reusable nuclear thermal propulsion stage (NTPS) to deliver cargo and crew to the Moon to establish a lunar base before undertaking human missions to Mars. The NTR option was selected by von Braun because it was a demonstrated technology capable of generating both high thrust and high specific impulse (Isp 900 s) twice that of todays best chemical rockets. In NASAs Mars Design Reference Architecture (DRA) 5.0 study, the crewed Mars transfer vehicle used three 25 klbf Pewee engines the smallest and highest performing engine tested in the Rover program along with graphite composite fuel. Smaller, lunar transfer vehicles consisting of a NTPS using three approximately 16.5 klbf Small Nuclear Rocket Engines (SNREs), an in-line propellant tank, plus the payload can enable a variety of reusable lunar missions. These include cargo delivery and crewed lunar landing missions. Even weeklong tourism missions carrying passengers into lunar orbit for a day of sightseeing and picture taking are possible. The NTR can play an important role in the next phase of lunar exploration and development by providing an affordable in-space lunar transportation system (LTS) that can allow initial outposts to evolve into settlements supported by a variety of commercial activities such as in-situ propellant production used to supply strategically located propellant depots and transportation nodes. The utilization of iron-rich volcanic glass or lunar polar ice (LPI) deposits (each estimated at billions of metric tons) for propellant production can significantly reduce the launch mass requirements from Earth and can enable reusable, surface-based lunar landing vehicles (LLVs) using liquid oxygen/hydrogen (LOX/LH2) chemical rocket engines. Afterwards, LOX/LH2 propellant depots can be established in lunar equatorial and polar orbits to supply the LTS. At this point a modified version of the conventional NTR called the LOX-augmented NTR, or LANTR would be introduced into the LTS allowing bipropellant operation and leveraging the mission benefits of refueling with lunar-derived propellants for Earth return. The bipropellant LANTR engine utilizes the large divergent section of its nozzle as an afterburner into which oxygen is injected and supersonically combusted with nuclear preheated hydrogen emerging from the engines choked sonic throat essentially scramjet propulsion in reverse. By varying the oxygen-to-hydrogen mixture ratio, LANTR engines can operate over a range of thrust and Isp values while the reactor core power level remains relatively constant. Eventually, a LANTR-based LTS can enable a rapid commuter shuttle with one-way trip times to and from the Moon ranging from 36 to 24 hours. Even if only 1 of the extracted propellant from identified volcanic glass and polar ice deposits were available for use in lunar orbit, such a supply could support daily commuter flights to the Moon for many thousands of years! An evolutionary mission architecture is outlined and a variety of lunar missions and transfer vehicle designs are examined, along with the increasing demands on propellant production as mission complexity increases. A comparison of vehicle features and engine operating characteristics, for both NTR and LANTR engines, is also provided along with a brief discussion on the propellant production issues associated with using volcanic glass and LPI as source material.

Spacecraft design↗