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NASA NTRSDate not supplied

Additive Manufacturing of ZrC for Nuclear Thermal Propulsion Applications

Looking into the future, we are seeing that nuclear is becoming a more and more viable fuel source for space applications due to it being one of the safest energy forms, low greenhouse gas emissions, and inexpensive maintenance. National Aeronautics and Space Administration (NASA) and a few others are looking at nuclear fuels in relation to space travel, specifically in the form of Nuclear Thermal Propulsion (NTP) [1]. NTP provides the answer for space travel to Mars where chemical rockets would not complete the job. A concept art of what these spacecrafts could look like is shown (Figure 1). Uranium Carbide fuel has been chosen to heat a liquid propellant for propulsion. The complex fuel geometries required by space reactors can be achieved by novel techniques fairly easily, cheaply, and safely. In this specific study, we are looking at using Zirconium Carbide (ZrC) to use as a surrogate for Uranium Carbide (UC) due to their similar behaviors under high temperatures. An ink made with ZrC will be made and will be extruded into unique, complex geometries. This is a great starting point to test additive manufacturing on these ceramics.

Additive Manufacturing↗

NASA NTRS2005

Realizing "2001: A Space Odyssey": Piloted Spherical Torus Nuclear Fusion Propulsion

A conceptual vehicle design enabling fast, piloted outer solar system travel was created predicated on a small aspect ratio spherical torus nuclear fusion reactor. The initial requirements were satisfied by the vehicle concept, which could deliver a 172 mt crew payload from Earth to Jupiter rendezvous in 118 days, with an initial mass in low Earth orbit of 1,690 mt. Engineering conceptual design, analysis, and assessment was performed on all major systems including artificial gravity payload, central truss, nuclear fusion reactor, power conversion, magnetic nozzle, fast wave plasma heating, tankage, fuel pellet injector, startup/re-start fission reactor and battery bank, refrigeration, reaction control, communications, mission design, and space operations. Detailed fusion reactor design included analysis of plasma characteristics, power balance/utilization, first wall, toroidal field coils, heat transfer, and neutron/x-ray radiation. Technical comparisons are made between the vehicle concept and the interplanetary spacecraft depicted in the motion picture 2001: A Space Odyssey.

Williams, Craig H.↗

NASA NTRS1993

Nuclear thermal propulsion technology: Results of an interagency panel in FY 1991

NASA LeRC was selected to lead nuclear propulsion technology development for NASA. Also participating in the project are NASA MSFC and JPL. The U.S. Department of Energy will develop nuclear technology and will conduct nuclear component, subsystem, and system testing at appropriate DOE test facilities. NASA program management is the responsibility of NASA/RP. The project includes both nuclear electric propulsion (NEP) and nuclear thermal propulsion (NTP) technology development. This report summarizes the efforts of an interagency panel that evaluated NTP technology in 1991. Other panels were also at work in 1991 on other aspects of nuclear propulsion, and the six panels worked closely together. The charters for the other panels and some of their results are also discussed. Important collaborative efforts with other panels are highlighted. The interagency (NASA/DOE/DOD) NTP Technology Panel worked in 1991 to evaluate nuclear thermal propulsion concepts on a consistent basis. Additionally, the panel worked to continue technology development project planning for a joint project in nuclear propulsion for the Space Exploration Initiative (SEI). Five meetings of the panel were held in 1991 to continue the planning for technology development of nuclear thermal propulsion systems. The state-of-the-art of the NTP technologies was reviewed in some detail. The major technologies identified were as follows: fuels, coatings, and other reactor technologies; materials; instrumentation, controls, health monitoring and management, and associated technologies; nozzles; and feed system technology, including turbopump assemblies.

Clark, John S.↗

NASA NTRS2012

Space Nuclear Power Systems

Fission power and propulsion systems can enable exciting space exploration missions. These include bases on the moon and Mars; and the exploration, development, and utilization of the solar system. In the near-term, fission surface power systems could provide abundant, constant, cost-effective power anywhere on the surface of the Moon or Mars, independent of available sunlight. Affordable access to Mars, the asteroid belt, or other destinations could be provided by nuclear thermal rockets. In the further term, high performance fission power supplies could enable both extremely high power levels on planetary surfaces and fission electric propulsion vehicles for rapid, efficient cargo and crew transfer. Advanced fission propulsion systems could eventually allow routine access to the entire solar system. Fission systems could also enable the utilization of resources within the solar system.

Houts, Michael G.↗

DOE OSTI2023

Low-Power Nuclear Heating Tests of UN Fuel Particles in Hydrogen Environment for Nuclear Thermal Propulsion

Recently, there has been a reemergence of interest within the space-exploration community regarding nuclear thermal propulsion (NTP) for interplanetary travel. NTP, as conceptualized, is a compact propulsion source, is relatively light because there is no need for an oxidizing agent and has a very high specific impulse compared to traditional forms of propulsion. These factors would reduce first-leg orbital-rocketry costs (by the source’s low weight and volume) and decrease overall travel time for astronauts with higher transit speeds. Idaho National Laboratory was provided bare, uncoated, and tungsten-coated uranium nitride fuel particles as part of a preliminary investigation. The fuel was fabricated by BWX Technologies and irradiated at the Massachusetts Institute of Technology research reactor. X-ray computed tomography and scanning electron microscopy and associated chemical analysis techniques were performed on these particles at Idaho National Laboratory. Both coated and uncoated forms were examined in the as-fabricated and as-irradiated conditions. The tungsten coating was found to be intact following the irradiation, indicating positive attributes for performance under these low-power-irradiation conditions. The irradiation of uncoated particles resulted in nitrogen enrichment at the edge of the particle.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2012

Nuclear Cryogenic Propulsion Stage

The fundamental capability of Nuclear Thermal Propulsion (NTP) is game changing for space exploration. A first generation Nuclear Cryogenic Propulsion Stage (NCPS) based on NTP could provide high thrust at a specific impulse above 900 s, roughly double that of state of the art chemical engines. Characteristics of fission and NTP indicate that useful first generation systems will provide a foundation for future systems with extremely high performance. The role of the NCPS in the development of advanced nuclear propulsion systems could be analogous to the role of the DC-3 in the development of advanced aviation. Progress made under the NCPS project could help enable both advanced NTP and advanced NEP.

Houts, Michael G.↗

NASA NTRS2012

Nuclear Cryogenic Propulsion Stage for Mars Exploration

Houts, M. G.↗

NASA NTRS2012

Affordable Development of a Nuclear Cryogenic Propulsion Stage

The fundamental capability of Nuclear Thermal Propulsion (NTP) is game changing for space exploration. A first generation Nuclear Cryogenic Propulsion Stage (NCPS) based on NTP could provide high thrust at a specific impulse above 900 s, roughly double that of state of the art chemical engines. The foundation provided by development and utilization of a NCPS could enable development of extremely high performance systems. The role of the NCPS in the development of advanced nuclear propulsion systems could be analogous to the role of the DC-3 in the development of advanced aviation. Progress made under the NCPS project could help enable both advanced NTP and advanced Nuclear Electric Propulsion (NEP).

Houts, M. G.↗

NASA NTRS2014

Safe, Affordable, Nuclear Thermal Propulsion Systems

Houts, M. G.↗

NASA NTRS2014

The Nuclear Cryogenic Propulsion Stage

The fundamental capability of Nuclear Thermal Propulsion (NTP) is game changing for space exploration. A first generation Nuclear Cryogenic Propulsion Stage (NCPS) based on NTP could provide high thrust at a specific impulse above 900 s, roughly double that of state of the art chemical engines. Characteristics of fission and NTP indicate that useful first generation systems will provide a foundation for future systems with extremely high performance. The role of the NCPS in the development of advanced nuclear propulsion systems could be analogous to the role of the DC-3 in the development of advanced aviation. Progres made under the NCPS project could help enable both advanced NTP and advanced Nuclear Electric Propulsion (NEP).

Houts, Michael G.↗

NASA NTRS2014

The Nuclear Cryogenic Propulsion Stage

Houts, Michael G.↗

NASA NTRS2012

Small Fast Spectrum Reactor Designs Suitable for Direct Nuclear Thermal Propulsion

Advancement of U.S. scientific, security, and economic interests through a robust space exploration program requires high performance propulsion systems to support a variety of robotic and crewed missions beyond low Earth orbit. Past studies, in particular those in support of the Space Exploration Initiative (SEI), have shown nuclear thermal propulsion systems provide superior performance for high mass high propulsive delta-V missions. The recent NASA Design Reference Architecture (DRA) 5.0 Study re-examined mission, payload, and transportation system requirements for a human Mars landing mission in the post-2030 timeframe. Nuclear thermal propulsion was again identified as the preferred in-space transportation system. A common nuclear thermal propulsion stage with three 25,000-lbf thrust engines was used for all primary mission maneuvers. Moderately lower thrust engines may also have important roles. In particular, lower thrust engine designs demonstrating the critical technologies that are directly extensible to other thrust levels are attractive from a ground testing perspective. An extensive nuclear thermal rocket technology development effort was conducted from 1955-1973 under the Rover/NERVA Program. Both graphite and refractory metal alloy fuel types were pursued. Reactors and engines employing graphite based fuels were designed, built and ground tested. A number of fast spectrum reactor and engine designs employing refractory metal alloy fuel types were proposed and designed, but none were built. The Small Nuclear Rocket Engine (SNRE) was the last engine design studied by the Los Alamos National Laboratory during the program. At the time, this engine was a state-of-the-art graphite based fuel design incorporating lessons learned from the very successful technology development program. The SNRE was a nominal 16,000-lbf thrust engine originally intended for unmanned applications with relatively short engine operations and the engine and stage design were constrained to fit within the payload volume of the then planned space shuttle. The SNRE core design utilized hexagonal fuel elements and hexagonal structural support elements. The total number of elements can be varied to achieve engine designs of higher or lower thrust levels. Some variation in the ratio of fuel elements to structural elements is also possible. Options for SNRE-based engine designs in the 25,000-lbf thrust range were described in a recent (2010) Joint Propulsion Conference paper. The reported designs met or exceeded the performance characteristics baselined in the DRA 5.0 Study. Lower thrust SNRE-based designs were also described in a recent (2011) Joint Propulsion Conference paper. Recent activities have included parallel evaluation and design efforts on fast spectrum engines employing refractory metal alloy fuels. These efforts include evaluation of both heritage designs from the Argonne National Laboratory (ANL) and General Electric Company GE-710 Programs as well as more recent designs. Results are presented for a number of not-yet optimized fast spectrum engine options.

Schnitzler, Bruce G.↗

NASA NTRSDate not supplied

Nuclear Space System Analysis and Modelling (NSSAM): A Software Tool to Efficiently Analyze the Design Space of Space Reactor Systems

Space reactors have the potential to play a key role in future NASA exploration activities due to their capability to enable sustainable power and advanced propulsion systems. To enable assessment of the space reactor design space, the nuclear space system analysis and modelling (NSSAM) software was developed by Analytical Mechanics Associates. NSSAM leverages a scalable and extensible software architecture which automates reactor analysis to perform coupled engine-reactor and reactor physics-thermal hydraulics calculations. This allows space reactor systems to be evaluated by a wider number of users with a consistent analysis approach to compare designs. NSSAM has been developed with multiple use cases to tailor the analysis to the level of detail desired by the user and computing resources. This summary overviews the NSSAM architecture and development approach, current capabilities (including design variants and use cases) and analysis approach for reactor and system component models.

nuclear thermal propulsion↗

NASA NTRS1991

Nuclear thermal propulsion program overview

Nuclear thermal propulsion program is described. The following subject areas are covered: lunar and Mars missions; national space policy; international cooperation in space exploration; propulsion technology; nuclear rocket program; and budgeting.

Bennett, Gary L.↗

NASA NTRS2014

Hot Hydrogen Testing of Tungsten-Uranium Dioxide (W-UO2) CERMET Fuel Materials for Nuclear Thermal Propulsion

CERMET fuel materials are being developed at the NASA Marshall Space Flight Center for a Nuclear Cryogenic Propulsion Stage. Recent work has resulted in the development and demonstration of a Compact Fuel Element Environmental Test (CFEET) System that is capable of subjecting depleted uranium fuel material samples to hot hydrogen. A critical obstacle to the development of an NCPS engine is the high-cost and safety concerns associated with developmental testing in nuclear environments. The purpose of this testing capability is to enable low-cost screening of candidate materials, fabrication processes, and further validation of concepts. The CERMET samples consist of depleted uranium dioxide (UO2) fuel particles in a tungsten metal matrix, which has been demonstrated on previous programs to provide improved performance and retention of fission products1. Numerous past programs have utilized hot hydrogen furnace testing to develop and evaluate fuel materials. The testing provides a reasonable simulation of temperature and thermal stress effects in a flowing hydrogen environment. Though no information is gained about radiation damage, the furnace testing is extremely valuable for development and verification of fuel element materials and processes. The current work includes testing of subscale W-UO2 slugs to evaluate fuel loss and stability. The materials are then fabricated into samples with seven cooling channels to test a more representative section of a fuel element. Several iterations of testing are being performed to evaluate fuel mass loss impacts from density, microstructure, fuel particle size and shape, chemistry, claddings, particle coatings, and stabilizers. The fuel materials and forms being evaluated on this effort have all been demonstrated to control fuel migration and loss. The objective is to verify performance improvements of the various materials and process options prior to expensive full scale fabrication and testing. Post test analysis will include weight percent fuel loss, microscopy, dimensional tolerance, and fuel stability.

Hickman, Robert↗

NASA NTRS2021

Martian Moons and Space Transportation Using Chemical and Electric Propulsion Options

Using chemical and nuclear electric propulsion for the exploration of the Martian moons will be investigated. Both oxygen/hydrogen chemical propulsion and nuclear electric propulsion with 500 kilowatt electric (kWe) to 10 megawatt electric (MWe) reactors will be assessed. The initial masses, propellant masses, and trip times for a variety of space vehicle payload masses will be compared. For high energy orbital transfer, the nuclear electric propulsion vehicles required a small fraction of the propellant mass over oxygen/hydrogen orbital transfer vehicles (OTVs). The moons, Phobos and Deimos, may hold resources for refueling future space vehicles. In-situ resource utilization (ISRU) can be a powerful method of reducing Earth dependence on space vehicle propellants, liquid water, and breathing gases. Historical studies have identified the potential of water in carbonaceous chondrites on the moons. The moon-derived propellants OTVs that move payloads between the moons and to other important operational Mars orbits. Also, the propellants have been suggested to support reusable Mars landers. To extract the water, the mined mass, its volume and the mining time were estimated. The water mass fraction may be as low as 2x10 −4 . Very large masses were needed to be extracted for up to 100 MT of water.

In-situ resource utilization↗

NASA NTRS2014

Affordable Development and Optimization of CERMET Fuels for NTP Ground Testing

CERMET fuel materials for Nuclear Thermal Propulsion (NTP) are currently being developed at NASA's Marshall Space Flight Center. The work is part of NASA's Advanced Space Exploration Systems Nuclear Cryogenic Propulsion Stage (NCPS) Project. The goal of the FY12-14 project is to address critical NTP technology challenges and programmatic issues to establish confidence in the affordability and viability of an NTP system. A key enabling technology for an NCPS system is the fabrication of a stable high temperature nuclear fuel form. Although much of the technology was demonstrated during previous programs, there are currently no qualified fuel materials or processes. The work at MSFC is focused on developing critical materials and process technologies for manufacturing robust, full-scale CERMET fuels. Prototypical samples are being fabricated and tested in flowing hot hydrogen to understand processing and performance relationships. As part of this initial demonstration task, a final full scale element test will be performed to validate robust designs. The next phase of the project will focus on continued development and optimization of the fuel materials to enable future ground testing. The purpose of this paper is to provide a detailed overview of the CERMET fuel materials development plan. The overall CERMET fuel development path is shown in Figure 2. The activities begin prior to ATP for a ground reactor or engine system test and include materials and process optimization, hot hydrogen screening, material property testing, and irradiation testing. The goal of the development is to increase the maturity of the fuel form and reduce risk. One of the main accomplishmens of the current AES FY12-14 project was to develop dedicated laboratories at MSFC for the fabrication and testing of full length fuel elements. This capability will enable affordable, near term development and optimization of the CERMET fuels for future ground testing. Figure 2 provides a timeline of the development and optimization tasks for the AES FY15-17 follow on program.

Hickman, Robert R.↗

NASA NTRS2007

Development of High Fidelity, Fuel-Like Thermal Simulators for Non-Nuclear Testing

Non-nuclear testing can be a valuable tool in development of a space nuclear power or propulsion system. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Work at the NASA Marshall Space Flight Center seeks to develop high fidelity thermal simulators that not only match the static power profile that would be observed in an operating, fueled nuclear reactor, but to also match the dynamic fuel pin performance during feasible transients. Comparison between the fuel pins and thermal simulators is made at the fuel clad surface, which corresponds to the sheath surface in the thermal simulator. Static and dynamic fuel pin performance was determined using SINDA-FLUINT analysis, and the performance of conceptual thermal simulator designs was compared to the expected nuclear performance. Through a series of iterative analysis, a conceptual high fidelity design will be developed, followed by engineering design, fabrication, and testing to validate the overall design process. Although the resulting thermal simulator will be designed for a specific reactor concept, establishing this rigorous design process will assist in streamlining the thermal simulator development for other reactor concepts.

Bragg-Sitton, S. M.↗