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At least 271 records · Page 15

Cold Spray Deposition of 304L Stainless Steel to Mitigate Chloride-Induced Stress Corrosion Cracking in Canisters for Used Nuclear Fuel Storage

A feasibility study of the cold spray deposition process of 304L stainless steel on 304L stainless steel substrates as a mitigation method for chloride-induced stress corrosion cracking (CISCC) has been investigated under various substrate conditions. The study is aimed at the application of this technology to mitigate CISCC that may potentially occur in or nearthe fusion welded regions of stainless steel canisters in Dry Cask Storage System (DCSS) for used nuclear fuels. Spherical gas-atomized 304L stainless steel powder, in the size range of 25 µm to 44 µm, was used as a feedstock powder for the cold spray process. The powder was deposited on four types of 304L substrates with various surface conditions: as-polished, oxidized, cold-rolled, plates with prototypical CISCC. The effects of cold spray parameters on quality of cold spray coatings were investigated. Thickness, porosity, and phases in the as-deposited materials were evaluated using scanning electron microscopy (SEM) and X-ray diffraction (XRD), and correlated with microhardness and adhesion strength measured via micro-indentation and ASTM C633 pulling test, respectively. XRD analysis of the coatings was also conducted to examine the effects of cold spray condition on residual stress state in the coating. Detailed cross-sectional examination of coating/substrate interfaces was performed with transmission electron microscopy (TEM) equipped with energy dispersive spectroscopy (EDS). Dense and continuous coatings with good adhesion strength and hardness were produced for the various substrate conditions by adjusting cold spray parameters. The results demonstrate that cold spray stainless steel coating is a viable option to provide a physical barrier against CISCC in fusion weld regions of stainless steel in corrosive chloride salt-bearing environments.

Dry Cask Storage Systems, cold spray, 304L stainle↗

Nano-Engineered Catalyst Supported on Ceramic Hollow Fibers for the Utilization of CO 2 in Dry Reforming to Produce Syngas

The objective of this project was to develop a novel catalytic reactor containing nano-engineered catalysts for the utilization of CO 2 (captured from coal-fired power plants and other CO 2 emitting sources) in dry methane reforming (DMR) (CO 2 + CH 4 → 2 H 2 + 2 CO) to produce synthesis gas (syngas). The technology aims to reduce CO2 emissions by developing beneficial uses for CO 2 from coal-fired power plants. It also offers an alternative to mitigate CO 2 emissions in areas where geologic storage may not be an optimal solution and/or utilization could significantly offset the costs of carbon capture and sequestration. The nano-engineered Ni-based catalyst was prepared by atomic layer deposition (ALD). The Ni particles were as small as ~2-4 nm. The nano-engineered catalyst showed CH 4 conversion >95%, H 2 /CO ratio in the range of 0.7-1.0, and CH 4 reforming rate as high as 2,500 L/h/gNi at 850 ºC and pressure of 15-25 psia. The Ni-based ALD catalyst also showed good stability in DMR reaction during a 200-h continuous operation at 850 °C. This is due to strong bonding between the nanoparticles and substrates since the Ni nanoparticles were chemically bonded to the substrate during the ALD process. The high thermal stability maintains the high dispersion of Ni nanoparticles, which can inhibit coke formation because their step edges are small enough to limit carbon nucleation and growth. Technoeconomic analysis (TEA) indicates the levelized cost of syngas (LCOS) is $172/ton with our technology, which is lower than the equivalent (molar) cost of hydrogen produced by steam methane reforming (SMR) or autothermal reforming (ATR). The major operating cost is natural gas feed and fuel, and the levelized cost is highly sensitive to the price of natural gas and relatively insensitive to the CAPEX. Revenues from syngas could have a significant impact on the net cost of electricity (COE), depending on the cost of natural gas and the selling price of syngas, estimated at $36 per MWh if the syngas were sold at $195 per ton. Following DOE NETL’s guidance, a lifecycle analysis (LCA) was conducted to compare with SMR. The functional unit for the basis of comparison was defined as 1kg carbon monoxide in the product stream. The global warming potential (GWP) of our process was found to be 40% lower than the state-of-the-art SMR process. The sensitivity analysis confirms the emissions are most sensitive to the natural gas fuel requirements to deliver heat to the process.

01 COAL, LIGNITE, AND PEAT↗

Advanced supersonic technology propulsion system study

This study had the objectives of determining the most promising conventional and variable cycle engine types; the effect of design cruise Mach number (2.2, 2.7 and 3.2) on a commercial supersonic transport; effect of advanced engine technology on the choice of engine cycle; and effect of utilizing hydrogen as the engine fuel. The technology required for the engines was defined, and the levels of development to ensure availability of this technology in advanced aircraft propulsion systems were assessed. No clearcut best conventional or variable cycle engine was identified. The dry bypass turbojet and the duct burning turbofans were initially selected as the best conventional engines, but later results, utilizing augmentation at takeoff, added the mixed-flow augmented turbofan as a promising contender. The modulating air flow, three-rotor variable cycle engine identified the performance features desired from VCE concepts (elimination of inlet drag and reduction in afterbody drag), but was a very heavy and complex engine.

Szeliga, R.↗

Space benefits: The secondary application of aerospace technology in other sectors of the economy

A benefits briefing notebook is presented for the NASA Technology Utilization Office in which 515 applications of NASA aerospace technology to other sections of the economy are described. An overview of technology transfer is given. Benefit cases are cited in 19 categories along with pertinent information, such as communication link, DRI transfer example file, and individual case number. General, organization, geographic, and field center indexes are provided.

Source record↗

Drop Analysis of Department of Energy Standard Canister with Fort Saint Vrain SNF

DOE manages over 300 types of SNF, most of which are located at the INL site. The Idaho Cleanup Project and INL are collaborating on the Road-Ready Capability Demonstration Project, which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF at the INL site for ?road-ready dry storage?. ?Road-ready dry storage? is a SNF management concept where SNF is packaged into dry and sealed canisters, which are then placed in on-site storage in anticipation of later transportation. The forward-looking goal of the Demonstration is establishing the foundation for a large-scale road-ready dry storage program at the INL site. The Demonstration will first package Fort Saint Vrain SNF currently stored at INL into several DOE Standard Canisters. These Standard Canisters will then be loaded into another commercial transportation or storage containment system (e.g., storage cask or transportation package). The Standard Canister is a class of standardized canisters designed for containing the large variety of DOE-managed SNF during interim storage, transportation and/or disposal at a geological repository. One critical aspect of road-ready dry storage is the ability to license the DOE Standard Canisters and its associated transportation package to 10 CFR 71. Depending on the SNF and transportation strategy, the Standard Canisters may have to maintain structural integrity under normal conditions of transport and hypothetical accident scenarios (i.e., drop events). The Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs. However, no analysis has been completed to support the recent Demonstration. This analysis will consider the Ø0.5 m × 5.1 m Standard Canister under drop scenario(s) considered in previous INL tests and analyses, including the 9 m drop at 80 degree off vertical. However, this analysis will consider the more recent Fort Saint Vrain loading configurations proposed for the Demonstration. This analysis will performed using strain-based acceptance criteria established by the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 3. It will be compared to previous analyses and form the foundation of further formal calculations that will be used to support licensing efforts of the road-ready dry storage system at INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Wyoming CarbonSAFE Phase III: Site Characterization and Permitting Commercial-Scale Carbon Storage Complex Feasibility Study at Dry Fork Station, Wyoming

This report presents the findings of the technical and non-technical site characterization and permitting activities (“Phase III”) conducted under the Wyoming CarbonSAFE: Accelerating CCUS Commercialization and Deployment at Dry Fork Power Station (DFS) and the Wyoming Integrated Test Center project (“Wyoming CarbonSAFE”). Wyoming CarbonSAFE is part of the U.S. Department of Energy’s (DOE) National Energy Technology Laboratory (NETL) Carbon Storage Assurance Facility Enterprise (“CarbonSAFE”) Initiative. The results of Phase III demonstrate that the Wyoming CarbonSAFE project - referred to as the Northern Powder River Basin Carbon Sequestration Hub (NPRB-CSH) - meets the technical, regulatory, and commercial feasibility requirements necessary to advance toward commercial development and construction. The activities completed under this project Phase make the NPRB-CSH one of the region’s most commercially ready carbon storage sites. Completion of this Phase included the finalization of all site surface and subsurface characterization activities, completion and testing of two Class VI standard wells, 10 draft Class VI permits-to construct to address the future needs of a storage complex, finalized NEPA assessments, transportation and capture FEED studies, and a full commercialization strategy with economic modeling, operation and site closure strategies. The NPRB-CSH meets all requirements to progress to a CarbonSAFE Phase IV program or advance to full commercial operations under the development of a business partner.

01 COAL, LIGNITE, AND PEAT↗

Multiple Stream Low-Cost Recycling Method

The global composite industry generates large quantities of waste and which mostly end as landfill due to lack of meaningful end-use applications for the multiple waste streams. In a recent report by the Electric Power Research Institute (EPRI), waste generated by the wind industry could reach 370,000 tons a year of composite wind energy blades being decommissioned and scrapped. Wind energy is just one major industry utilizing composite materials. The waste generated by industry includes End-of-Life (EoL) materials and manufacturing process scrap. GreenTex Solutions has developed a unique and innovative technology to recycle the composite waste streams in a range of forms made from production waste and EoL materials. This includes manufacturing waste materials such as dry chopped fiber tow, loose fibers, shredded fibers from reinforcement fabrics, cured/semi-cured prepregs, and it also includes fully-cured composite structure waste (such as edge trims from cured parts) from manufacturing aircraft, automobiles, wind blades, boats, and composite cylinders (tanks). Current recycling methods involve recovering the structural fiber by removing the matrix resin through methods such as pyrolysis. The resulting fibers are used in injection molding or wet laid nonwoven mats and other usable forms. The GreenTex technology bypasses these intermediate steps to create the lowest possible recycling processing costs and the lowest embodied energy/CO2 emissions. The end-product from the GreenTex technology is a finished industrial composite part/application versus intermediate fibers or fabrics. The GreenTex manufacturing process enables cross-industry reuse of recycled feedstock by taking waste from multiple industries (wind energy, aerospace, marine, etc.) and recycles the waste into a product used in other industries. The initial target market application is structural flooring for intermodal shipping containers and truck bodies. One of the team’s key partners is Wabash National which produced 29,000 truck bodies in 2019. The current flooring system is comprised of solid oak “butcher board” laminated panels. Additionally, Mediterranean Shipping Containers (MSC) transports over 1.8 million twenty-foot equivalent units per year in intermodal shipping containers. The current container floor is laminated hardwood that is harvested from the rain forests of Central and South America. The project is to develop a flooring system made from recycled composites that can be qualified for both companies (Wabash and MSC). Initial prototypes validated that the recycled composites panels are lighter and thinner with much higher mechanical strength. These results suggest a typical truck trailer would have 20% lower tare weight. The GreenTex technology is not limited to flooring and is widely applicable to other transportation elements such as walls, roof elements, cab areas and related structural components. Under this project different composite waste streams were evaluated and then combined to develop a formulation that would meet the targeted performance criteria for a flooring system. Wet compression molding was used to fabricate plaques at different tonnage using various composite waste streams. The plaques were tested for flexure and impact.

36 MATERIALS SCIENCE↗

Configuration and Projected Capabilities of the Common Habitat Medical Care Facility

The Common Habitat is a large, long-duration habitat being explored as part of a conceptual study (not an active NASA program) that uses an SLS core stage Liquid Oxygen (LOX) tank as its primary structure. It is intended for use on the Moon as part of a permanently occupied outpost, on Mars as part of an outpost that will be occupied for hundreds of days at a time, and in deep space as part of the Deep Space Exploration Vehicle where it will support crewed missions up to 1200 days in duration. A study of internal orientation and crew size resulted in a Common Habitat configuration sized for a crew of eight with a three-deck horizontal orientation. Additional work outside the scope of this paper is developing a vertical translation system, a crew mobility aids system based on wearable gecko-derived grippers, and a crew seating/restraint system. These systems are all assumed for use in conjunction with the Medical Care Facility, which is needed to maintain crew well-being during these missions, where distance from Earth precludes the possibility of evacuation to Earth. This paper describes recent improvements in the Common Habitat Medical Care Facility and associated benefits for crew survivability in long duration missions beyond Earth orbit. These improvements were made with the assistance of a NASA Pathways intern whose experience includes a tour of duty in Afghanistan as an Army combat medic with the 691st GHOST-T, attached to the 1st and 7th US Special Forces Groups as part of Operation Freedom’s Sentinel, where he helped provide far-forward surgical capabilities in austere combat environments. The initial baseline Medical Care Facility was developed working in conjunction with University of Houston Space Architecture graduate students. The facility was placed on the upper deck of the Common Habitat in a location that provided privacy, operational volume, and was close to the vertical translation pathway. The notional outfitting repurposed component CAD models from unrelated studies and notionally indicated a level of care roughly equivalent to that aboard the International Space Station. The CAD modeling provided notional stowage volumes, a deployable surface, some fixed equipment, an ultrasound, and a potentially reconfigurable treatment table. While this facility is clearly a competent arrangement, it was desired to leverage available expertise and upgrade the station given the vast distances from Earth to be experienced by the Common Habitat. Key driving requirements applied to the upgrade included to provide Medical Level of Care V, offer enhanced telemedicine capabilities, provide patient physical accommodation, provide caregiver access to the patient from all sides, include sliding pocket doors for access to hygiene and to the Vertical Translation System, and to add any additional capability possible for the best achievable medical care. The first step in the facility upgrade was to quantify the current medical inventory on the International Space Station and ensure that sufficient stowage volume was present for this purpose. To that end, the ISS medical kits were reviewed, and eight full size mid deck lockers were placed in the facility. A number of additional devices were also added, based on the intern’s combat medic experience. Also, two fixed shelves and one horizontal work surface were added to the Medical Care Facility, with the shelves providing storage space for the additional devices and the work surface providing a location for the caregiver to work or stage equipment. Four display monitors were added to the wall above the horizontal work surface, supporting data display, telemedicine, conferencing, or other needs. The existing treatment table was replaced with a mobile surgical stretcher-chair. Two additional doors were added to the Medical Care Facility. One leads directly to the hygiene compartment, allowing it to support medical operations in addition to providing galley/wardroom support. The other door leads directly into the Vertical Translation System. The wall adjacent to the subsystems bay was moved, adding additional volume to the Medical Care Facility. This improved caregiver access to the patient and allowed for a larger number of caregivers to be present. It also provided options for relocation of support equipment relative to the patient as needed. In the upgraded Medical Care Facility, the Surgical Stretcher-Chair and the Vertical Translation System can work together to provide incapacitated crew member transport from a site of injury on any deck of the Common Habitat to the Medical Care Facility. It can also support patient treatment in a variety of positions including a variety of sitting postures and a supine posture at a variety of pitch angles. The facility can also support caregiver office work for review of examination results, private consultation, inventory and maintenance, and a variety of other purposes. A forward activity will be to conduct evaluations of the Medical Care Facility with different medical scenarios. Additionally, ambient and task lighting selections remain as forward work. The eight mid deck lockers can be augmented to use as portable equipment carts, similar to a manner in which maintenance facility stowage was used as portable carts during the NASA Desert Research and Technology Studies in the Constellation Program. Trash accommodation will also need forward work to assess, including provision for wet trash, dry trash, and biological waste. It will be important to assess a redesign of the surgical stretcher-chair. The commercial version used in the upgrade can only enable vertical translation in the seated configuration, requiring the patient to bend both hips and knees. A possible redesign of the chair will allow for vertical translation without requiring any bending at the hip or knees. Also, the commercial version is wheeled, making it mobile in gravity but unanchored in microgravity. Work will be needed to adapt the chair for gravity-independent performance. The hygiene compartment can be redesigned for dual-use medical scrub and galley handwash facility. Pending sufficient volume, it may also be possible to place sanitation equipment in this location to clean medical tools. Finally, most space architectures have never allowed for more than one incapacitated crew member, but several scenarios could potentially injure two or more crew in the same incident. This facility could be assessed to determine its present ability to address two or more injured crew in parallel and determine the potential upper limit for number of treatable crew in a multi-crew injury scenario, or to treat polytrauma of a single patient.

Habitat↗

Configuration and Projected Capabilities of the Common Habitat Medical Care Facility

The Common Habitat is a large, long-duration habitat being explored as part of a conceptual study (not an active NASA program) that uses an SLS core stage Liquid Oxygen (LOX) tank as its primary structure. It is intended for use on the Moon as part of a permanently occupied outpost, on Mars as part of an outpost that will be occupied for hundreds of days at a time, and in deep space as part of the Deep Space Exploration Vehicle where it will support crewed missions up to 1200 days in duration. A study of internal orientation and crew size resulted in a Common Habitat configuration sized for a crew of eight with a three-deck horizontal orientation. Additional work outside the scope of this paper is developing a vertical translation system, a crew mobility aids system based on wearable gecko-derived grippers, and a crew seating/restraint system. These systems are all assumed for use in conjunction with the Medical Care Facility, which is needed to maintain crew well-being during these missions, where distance from Earth precludes the possibility of evacuation to Earth. This paper describes recent improvements in the Common Habitat Medical Care Facility and associated benefits for crew survivability in long duration missions beyond Earth orbit. These improvements were made with the assistance of a NASA Pathways intern whose experience includes a tour of duty in Afghanistan as an Army combat medic with the 691st GHOST-T, attached to the 1st and 7th US Special Forces Groups as part of Operation Freedom’s Sentinel, where he helped provide far-forward surgical capabilities in austere combat environments. The initial baseline Medical Care Facility was developed working in conjunction with University of Houston Space Architecture graduate students. The facility was placed on the upper deck of the Common Habitat in a location that provided privacy, operational volume, and was close to the vertical translation pathway. The notional outfitting repurposed component CAD models from unrelated studies and notionally indicated a level of care roughly equivalent to that aboard the International Space Station. The CAD modeling provided notional stowage volumes, a deployable surface, some fixed equipment, an ultrasound, and a potentially reconfigurable treatment table. While this facility is clearly a competent arrangement, it was desired to leverage available expertise and upgrade the station given the vast distances from Earth to be experienced by the Common Habitat. Key driving requirements applied to the upgrade included to provide NASA’s Medical Level of Care V, offer enhanced telemedicine capabilities, provide patient physical accommodation, provide caregiver access to the patient from all sides, include sliding pocket doors for access to hygiene and to the Vertical Translation System, and to add any additional capability possible for the best achievable medical care. The first step in the facility upgrade was to quantify the current medical inventory on the International Space Station and ensure that sufficient stowage volume was present for this purpose. To that end, the ISS medical kits were reviewed, and eight full size mid deck lockers were placed in the facility. A number of additional devices were also added, based on the co-author’s combat medic experience. Also, two fixed shelves and one horizontal work surface were added to the Medical Care Facility, with the shelves providing storage space for the additional devices and the work surface providing a location for the caregiver to work or stage equipment. Four display monitors were added to the wall above the horizontal work surface, supporting data display, telemedicine, conferencing, or other needs. The existing treatment table was replaced with a mobile surgical stretcher-chair. Two additional doors were added to the Medical Care Facility. One leads directly to the hygiene compartment, allowing it to support medical operations in addition to providing galley/wardroom support. The other door leads directly into the Vertical Translation System. The wall adjacent to the subsystems bay was moved, adding additional volume to the Medical Care Facility. This improved caregiver access to the patient and allowed for a larger number of caregivers to be present. It also provided options for relocation of support equipment relative to the patient as needed. In the upgraded Medical Care Facility, the Surgical Stretcher-Chair and the Vertical Translation System can work together to provide incapacitated crew member transport from a site of injury on any deck of the Common Habitat to the Medical Care Facility. It can also support patient treatment in a variety of positions including a variety of sitting postures and a supine posture at a variety of pitch angles. The facility can also support caregiver office work for review of examination results, private consultation, inventory and maintenance, and a variety of other purposes. A forward activity will be to conduct evaluations of the Medical Care Facility with different medical scenarios. Additionally, ambient and task lighting selections remain as forward work. The eight middeck lockers can be augmented to use as portable equipment carts, similar to a manner in which maintenance facility stowage was used as portable carts during the NASA Desert Research and Technology Studies in the Constellation Program. Trash accommodation will also need forward work to assess, including provision for wet trash, dry trash, and biological waste. It will be important to assess a redesign of the surgical stretcher-chair. The commercial version used in the upgrade can only enable vertical translation in the seated configuration, requiring the patient to bend both hips and knees. A possible redesign of the chair will allow for vertical translation without requiring any bending at the hip or knees. Also, the commercial version is wheeled, making it mobile in gravity but unanchored in microgravity. Work will be needed to adapt the chair for gravity-independent performance. The hygiene compartment can be redesigned to serve both as a medical scrub facility and for galley hand washing. Pending sufficient volume, it may also be possible to place sanitation equipment in this location to clean medical tools. Finally, most space architectures have never allowed for more than one incapacitated crew member, but several scenarios could potentially injure two or more crew in the same incident. This facility could be assessed to determine its present ability to address two or more injured crew in parallel and determine the potential upper limit for number of treatable crew in a multi-crew injury scenario, or to treat polytrauma of a single patient.

Common Habitat↗

ISAAC Integrated Structural Assembly of Advanced Composites

The NASA Langley Research Center obtained the Integrated Structural Assembly of Advanced Composites (ISAAC) robotic system in 2014 to add state-of-the-art automated manufacturing of composites to our traditional in-house design, analysis, and experimentation capabilities. ISAAC is used to explore fabrication of parts with novel designs and for research into new composite manufacturing techniques. Automated fiber placement (AFP) was the initial manufacturing capability on ISAAC and has been used to support a range of aeronautics and space projects including the Advanced Composites Project (ACP), Composites for Exploration Upper Stage (CEUS), and Advanced Air Transportation Technologies (AATT). In addition to AFP, ISAAC can now provide through-thickness reinforcement of composites by adding stitches through dry fabric prior to resin infusion. Stitching is of interest since it can improve damage tolerance, reduce final assembly time, and reduce inspection requirements. ISSAC can stitch traditional single-needle seams and perform stitching operations using two needles when access is only available to one side of the part. Stitching capability is being advanced in the High-Rate Composites Aircraft Manufacturing (HiCAM) project today. This lecture will describe the work with ISAAC today and new exciting plans for the future.

automated fiber placement↗

A centrifuge CO2 pellet cleaning system

An advanced turbine/CO2 pellet accelerator is being evaluated as a depaint technology at Oak Ridge National Laboratory (ORNL). The program, sponsored by Warner Robins Air Logistics Center (ALC), Robins Air Force Base, Georgia, has developed a robot-compatible apparatus that efficiently accelerates pellets of dry ice with a high-speed rotating wheel. In comparison to the more conventional compressed air 'sandblast' pellet accelerators, the turbine system can achieve higher pellet speeds, has precise speed control, and is more than ten times as efficient. A preliminary study of the apparatus as a depaint technology has been undertaken. Depaint rates of military epoxy/urethane paint systems on 2024 and 7075 aluminum panels as a function of pellet speed and throughput have been measured. In addition, methods of enhancing the strip rate by combining infra-red heat lamps with pellet blasting and by combining the use of environmentally benign solvents with the pellet blasting have also been studied. The design and operation of the apparatus will be discussed along with data obtained from the depaint studies.

Foster, C. A.↗

Control System Development for A Zero Boil-Off Hydrogen Storage Demonstration With Two-Stage Active Cooling

A NASA team is designing and building a test article to demonstrate the long duration storage of liquid hydrogen via active cooling (cryocoolers) while implementing a two-stage cooling approach. This activity is one of a large portfolio of NASA’s Space Technology Mission Directorate funded activities which focuses on the technology maturation needed for long duration storage of cryogenic liquid in-space. The current state-of-the-art for liquid hydrogen storage on-orbit is on the order of hours while NASA’s planned missions require storage for months, or even years. To enable such a long duration, Zero Boil-Off conditions must be achieved which requires passive technologies to minimize environmental heat loads, but also active cooling to intercept and reject the remaining heat to deep space. The implementation of active cooling results in a significant amount of dry mass added to the vehicle. Utilizing a Two-Stage Cooling approach, analysis and testing to date indicates the Zero Boil-Off of liquid hydrogen can be achieved with less mass and electrical power relative to a single-stage cooling approach where only one cryocooler is used. This activity will demonstrate the fully integrated suite of technologies needed to enable the Two-Stage Cooling approach which includes Multi-Layer Insulation blankets, Low Conductivity Structures, a Tube-On-Tank Heat Exchanger, Tube-On-Shield Heat Exchanger and a Two-Stage Cryogenerator (both 90 Kelvin and 20 Kelvin) with each stage having an independently controlled circulation loop. The bulk of the heat load is intercepted by the 90 Kelvin loop via a thin foil heat exchanger internal to the insulation blankets (also known as a Broad Area Cooling Shield), with the remainder removed at cryofluid temperature (20 Kelvin) by tubes directly welded to the outer tank surface. In this paper, we examine the challenges of controlling the system, and describe the development of control algorithms and software for future testing with liquid hydrogen. The interactions between the cryofans which control circulation loop mass flow rates, electrical heaters which vary the cryocooler lift to simulate the operation of variable-lift flight units, tank heaters which can vary the overall heat load, and the effects of changes in circulation loop pressure as temperatures change, can be complex and must be well understood to maintain steady-state propellant conditions and achieve Zero Boil-Off. Parallel PID loops and watchdog programs implemented on the user interface system will help bring the systems to steady state operation and keep them at selected operating points within acceptable error, while avoiding runaway feedback loops.

cryogenics↗

Ultrasonic Washer–Dryer System for Space Habitats: Design Upgrades and Parabolic Flight Readiness

Clothing makes up nearly 25% of all non-food supplies sent to the International Space Station (ISS). To support sustainable human missions in deep space, NASA’s Life Support and Habitation Systems Focus Area looks to advance technologies to support and improve logistics. Our team is creating a compact ultrasonic clothing washer/dryer system that bypasses traditional limitations and is suitable for space. Thermal drying uses a lot of energy to evaporate water, while our ultrasonic drying method offers a quicker, more efficient alternative. It uses piezoelectric transducers to vibrate textiles at the micron scale, mechanically removing water as cold mist rather than evaporating it. This speeds up drying and reduces energy use, no matter the fabric makeup. This paper details recent upgrades to a full-scale ultrasonic washer–dryer system, readying it for parabolic flight testing. Improvements include an enhanced human–machine interface, better packaging, and optimized performance and control. We also present extensive pre-flight ground tests conducted to ensure reliability and identify potential risks. Collaborating with P&G, we report preliminary cleaning tests using various detergents. These results lay a crucial foundation for the laundry system designed specifically for space. By cutting clothing-related payload and waste by over 97%, this technology supports long-term human exploration missions on the ISS, the Moon, Mars, and beyond.

Ultrasonic↗

Ultrasonic Washer–Dryer System for Space Habitats: Design Upgrades and Parabolic Flight Readiness

Clothing makes up nearly 25% of all non-food supplies sent to the International Space Station (ISS). To support sustainable human missions in deep space, NASA’s Life Support and Habitation Systems Focus Area looks to advance technologies to support and improve logistics. Our team is creating a compact ultrasonic clothing washer/dryer system that bypasses traditional limitations and is suitable for space. Thermal drying uses a lot of energy to evaporate water, while our ultrasonic drying method offers a quicker, more efficient alternative. It uses piezoelectric transducers to vibrate textiles at the micron scale, mechanically removing water as cold mist rather than evaporating it. This speeds up drying and reduces energy use, no matter the fabric makeup. This paper details recent upgrades to a full-scale ultrasonic washer–dryer system, readying it for parabolic flight testing. Improvements include an enhanced human–machine interface, better packaging, and optimized performance and control. We also present extensive pre-flight ground tests conducted to ensure reliability and identify potential risks. Collaborating with P&G, we report preliminary cleaning tests using various detergents. These results lay a crucial foundation for the laundry system designed specifically for space. By cutting clothing-related payload and waste by over 97%, this technology supports long-term human exploration missions on the ISS, the Moon, Mars, and beyond.

Laundry↗

Comparative life cycle assessment of woody biomass processing: air classification, drying, and size reduction powered by bioelectricity versus grid electricity

Sulfur accumulation during biofuel production is pollutive and toxic to conversion catalysts and causes the premature breakdown of processing equipment. Air classification is an effective preprocessing technology for ash and sulfur reduction from biomass feedstocks. Here, a life cycle assessment (LCA) sought to understand the environmental impact of implementing air classification as a sulfur-mitigation technique to improve feedstock quality for pine residues using a grid electricity scenario (GES) versus a bioelectricity scenario (BES). Global warming potential (GWP) for preprocessing was simulated using inventory databases embedded in SimaPro and the Argonne National Laboratory’s GREET model, specifically focusing on comparing the GWP of a GES versus a BES. Overall, the GES had a GWP impact over seven times that of the BES (136 versus 18 kg CO 2 equivalent per tonne of usable feedstock), with steam generation during rotary drying accounting for 57% of the GES’s GWP. Air classification represents 0.4% and 1.6% of the total GWP impact for the GES and BES, respectively. Therefore, air classification can facilitate a 30% reduction in feedstock sulfur content to improve feedstock quality for biofuel conversion and lessen corrosion of equipment while contributing minimal GWP impact during preprocessing.

Air classification↗

Energy 101 Geothermal [Slides]

The Energy 101: Geothermal presentation, developed for the Energy Technology Innovation Partnership Project (ETIPP), provides an overview of geothermal energy. It covers fundamental concepts, technologies, considerations, case studies, and additional resources.

15 GEOTHERMAL ENERGY↗

Electrospray Thruster Performance with Microfabricated Emitter Arrays and Indium Propellant

The feasibility of a microfabricated indium-fueled electrospray thruster with excellent performance was demonstrated. High efficiency electrospray thrusters with microfabricated components are under development for very compact, distributable propulsion systems that can be employed on both very small and large spacecraft with 10X improvement over SOA in mass, volume and specific impulse The critical components of this technology are the microfabricated emitter arrays and the capillary force driven indium feed system. Grey scale electron-beam lithography patterning and reactive ion dry etching provided the required micron-scale etch precision and uniformity across an array of 400 emitters in 1 cm2. Initial tests of single microfabricated silicon emitters demonstrated better performance than industry standard single emitters and the performance required to achieve 200 micronewtons when scaled up to a thruster with 400 emitters in 1 cm2. Arrays of emitters tested in a preliminary prototype Microfluidic Electrospray Propulsion (MEP) thruster assembly demonstrated stable performance at estimated thrust levels of 5, 50, and 120 µN at extraction voltages less than 4 kV. Current stability was within 0.15 % at 120 µN with only 1.5% of the emitter current collected by the extractor electrode. Post-test inspections revealed that more than 99% of the 400 emitters were electrospraying during the test. Specific impulse was estimated to be >3100 s from measurements of total charge and consumed indium mass at an emitter voltage of 1470 V. The results of this investigation suggest that microfabricated indium electrospray thruster technology is both feasible and capable of excellent performance as a highly compact microthruster.

Marrese-Reading, Colleen M.↗