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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.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS1971

A study of alternative methods for reclaiming oxygen from carbon dioxide and water by a solid-electrolyte process for spacecraft applications

Two alternative technical approaches were studied for application of an electrochemical process using a solid oxide electrolyte (zirconia stabilized by yttria or scandia) to oxygen reclamation from carbon dioxide and water, for spacecraft life support systems. Among the topics considered are the advisability of proceeding to engineering prototype development and fabrication of a full scale model for the system concept, the optimum choice of method or approach to be carried into prototype development, and the technical problem areas which exist.

Source record↗
NASA NTRS2010

Launch Pad Coatings for Smart Corrosion Control

Corrosion is the degradation of a material as a result of its interaction with the environment. The environment at the KSC launch pads has been documented by ASM International (formerly American Society for Metals) as the most corrosive in the US. The 70 tons of highly corrosive hydrochloric acid that are generated by the solid rocket boosters during a launch exacerbate the corrosiveness of the environment at the pads. Numerous failures at the pads are caused by the pitting of stainless steels, rebar corrosion, and the degradation of concrete. Corrosion control of launch pad structures relies on the use of coatings selected from the qualified products list (QPL) of the NASA Standard 5008A for Protective Coating of Carbon Steel, Stainless Steel, and Aluminum on Launch Structures, Facilities, and Ground Support Equipment. This standard was developed to establish uniform engineering practices and methods and to ensure the inclusion of essential criteria in the coating of ground support equipment (GSE) and facilities used by or for NASA. This standard is applicable to GSE and facilities that support space vehicle or payload programs or projects and to critical facilities at all NASA locations worldwide. Environmental regulation changes have dramatically reduced the production, handling, use, and availability of conventional protective coatings for application to KSC launch structures and ground support equipment. Current attrition rate of qualified KSC coatings will drastically limit the number of commercial off the shelf (COTS) products available for the Constellation Program (CxP) ground operations (GO). CxP GO identified corrosion detection and control technologies as a critical, initial capability technology need for ground processing of Ares I and Ares V to meet Constellation Architecture Requirements Document (CARD) CxP 70000 operability requirements for reduced ground processing complexity, streamlined integrated testing, and operations phase affordability. Researchers at NASA's Corrosion Technology Laboratory at KSC are developing a smart, environmentally friendly coating system for early corrosion detection, inhibition, and self healing of mechanical damage without external intervention. This smart coating will detect and respond actively to corrosion and mechanical damage such as abrasion and scratches, in a functional and predictable manner, and will be capable of adapting its properties dynamically. This coating is being developed using corrosion sensitive microcapsules that deliver the contents of their core (corrosion inhibiting compounds, corrosion indicators, and self healing agents) on demand when corrosion or mechanical damage to the coating occurs.

Calle, Luz M.↗
NASA NTRS1986

Experimental evaluation of candidate carbon-carbon materials for OTV engine nozzle extensions

Advanced carbon-carbon nozzle materials can reduce the weight and improve the efficiency of the proposed reusable Orbit Transfer Vehicle (OTV) liquid rocket engine. Experimental evaluations of eight carbon-carbon materials in an O2/H2 rocket nozzle environment have been performed. The hot fire testing will support the choice of the materials for the OTV nozzle design. The OTV nozzle requirements and operating environment are defined. The rocket device used to simulate the OTV hot-fire nozzle environment for material specimen evaluation is described. The results of hot-fire testing for eight carbon-carbon materials are discussed. Results for coated and uncoated materials, evaluated in side-by-side testing, are compared. Plans for further testing of the leading materials are described.

Suhoza, J. P.↗
NASA NTRS2015

Improving Interlaminar Shear Strength

To achieve NASA's mission of space exploration, innovative manufacturing processes are being applied to the fabrication of complex propulsion elements.1 Use of fiber-reinforced, polymeric composite tanks are known to reduce weight while increasing performance of propulsion vehicles. Maximizing the performance of these materials is needed to reduce the hardware weight to result in increased performance in support of NASA's missions. NASA has partnered with the Mississippi State University (MSU) to utilize a unique scalable approach of locally improving the critical properties needed for composite structures. MSU is responsible for the primary development of the concept with material and engineering support provided by NASA. The all-composite tank shown in figure 1 is fabricated using a prepreg system of IM7 carbon fiber/CYCOM 5320-1 epoxy resin. This is a resin system developed for out-of-autoclave applications. This new technology is needed to support the fabrication of large, all composite structures and is currently being evaluated on a joint project with Boeing for the Space Launch System (SLS) program. In initial efforts to form an all composite pressure vessel using this prepreg system, a 60% decrease in properties was observed in scarf joint regions. Inspection of these areas identified interlaminar failure in the adjacent laminated structure as the main failure mechanism. This project seeks to improve the interlaminar shear strength (ILSS) within the prepreg layup by locally modifying the interply region shown in figure 2.2

Jackson, Justin↗
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.↗
NASA NTRS1991

Reaction engineering for materials processing in space: Reduction of ilmenite by hydrogen and carbon monoxide

Oxygen is a consumable material which needs to be produced continuously in most space missions. Its use for propulsion as well as life support makes oxygen one of the largest volume chemicals to be produced in space. Production of oxygen from lunar materials is of particular interest and is very attractive possibility. The kinetics and mechanism of reduction of ilmenite by carbon monoxide and hydrogen at 800 to 1100 C were investigated. The temporal profiles of conversion for carbon monoxide have a sigmoidal shape and indicate the presence of three different stages (induction, acceleration, and deceleration) during the reduction reaction. The apparent activation energy decreases from 18 kcal/mole at 10 percent conversion to 10 kcal/mole at 50 percent conversion. The reaction is first order with respect to carbon monoxide under the experimental conditions studied. Both SEM and EDX analysis show that the diffusion of Fe product away from the reaction front and through the TiO2 phase, followed by the nucleation and growth of a separate Fe phase are important steps affecting the process kinetics. The results from hydrogen reduction show that the mechanism of ilmenite reduction by hydrogen is similar to that by carbon monoxide. However, the titanium dioxide can be further reduced by hydrogen at 800 to 1000 C. The detailed comparison and theoretical modeling of both reduction processes is presented.

Zhao, Y.↗
NASA NTRS2004

Development of Columbia Leading Edge Reconstruction System

After the loss of Columbia in 2003, the Columbia Accident Investigation Board and NASA KSC directed personnel at the Launch Equipment Test Facility (LETF) to design and build high fidelity mock-ups of Columbia's left wing leading edges. These leading edge segments, constructed of reinforced carbon-carbon, were a major point of inquiry by the investigation team. The LETF engineers developed a concept of building a clear Lexan panel with an aluminum support structure ten percent larger than the original panel. The leading edge debris are attached to the Lexan panels and both the front and back side of each panel are visible for inspection. The entire assembly can be rotated, to provide visual access to the entire panel. Six carts were fabricated to support the thirteen panels. These carts could be set up in order, next to each other, to provide the desired inspection access. The carts and attached debris are currently located in the Vehicle Assembly Building at KSC.

Trautwein, John↗
NASA NTRS2024

Characterization of NUW-LHT-5m, A Lunar Highland Simulant

A new simulant of the lunar highlands regolith, NUW-LHT-5M, was designed by NASA and manufactured by Washington Mills. The simulant was based on Apollo 16 data and is a member of the NU-LHT-series. NASA’s Marshall Space Flight Center and Johnson Space Center have already purchased 3 metric tons of the simulant for advanced engineering work. In support of engineering uses of the simulant, we provided measurements of the simulant including: mineral abundance and composition, liberation, X-ray fluorescence (XRF), ferrous iron, carbon, sulfur, 60 element inductively coupled plasma (ICP), loss on ignition, particle size, both 2D and 3D particle shape, specific surface area, shear, cohesion, internal friction, helium pycnometry, minimum index density, tap density, magnetic susceptibility, cryogenic and high temperature permittivity, visible and near-infrared (VNIR) and middle infra-red spectroscopy (MIR), differential scanning calorimetry (DSC), viscosity, thermal diffusivity, thermal conductivity, thermal gravimetric analysis (TGA), evolved gas analysis (EGA), and spark sintering. For the crystalline components the design of the simulant called for two rocks from the Stillwater Complex, Montana: 17.6 wt% norite, 37.7% anorthosite, and 4.7 wt% olivine from an unspecified commercial source. The other 40% of the simulant was a high calcium (An100), vesicular glass that Washington Mills made specifically for the simulant. Fabrication and quality control processes for both the glass and the simulant are described. Importantly, most of the graphs and tables presented herein provide values for both the new simulant and data for the older NASA mare simulant, JSC-1A. Finally, we discussed the current limitations of NUW-LT-5M and most other lunar regolith simulants to replicate the lunar material.

lunar regolith simulant↗
NASA NTRSDate not supplied

Status of the Development of 3MDCP, the 3-D Woven TPS enabling the Mars Sample Return Earth Entry System

- The Mars Sample Return Earth Entry System is being designed to withstand entry environments of: - Peak Heat Flux of > 3000 W/cm2 - Peak Dynamic Pressure of > 2 atmospheres - Peak Shear of > 3000 Pa. - The TPS Material System Selected to support MSR EES is “3MDCP”, 3D Mid Density Carbon Phenolic. 3MDCP is a derivative of the HEEET material system, using the “Insulation Layer” only. - Implementation of 3MDCP on EES is monolithic instead of a tile architecture in order to meet MSR reliability demands. - The EES TPS Team has recently completed a number of major engineering development milestones in support of delivering the flight 3MDCP TPS hardware: - Weaving Scale-Up completed, > 80” width woven preform production underway - Full Scale Forming & Manufacturing Attrition completed to verify delivered thickness capabilities. - Recent Design Change: EES design has been changed from a 45 degree sphere cone to a 52.5 degree sphere cone to allow for additional system mass.

Z. Young↗
NASA NTRS2020

Emission Characteristics of an Axially Staged Sector Combustor for a Small Core High OPR Subsonic Aircraft Engine

This paper presents the nitrogen oxides, carbon monoxide, and particulate matter emissions of a single sector axially staged combustor sector designed and fabricated by United Technologies Research Center (UTRC) in partnership with NASA under a compact low-emissions combustor contract supported by the NASA Advanced Air Transport Technology (AATT) N+3 project. The test was conducted at NASA Glenn Research Center's CE-5 combustion test facility. The facility provided inlet air temperatures up to 922 K and pressures up to 19.0 bar. The combustor design concept, called Axially Controlled Stoichiometry (ACS), was developed by Pratt & Whitney (P&W) under NASA's Environmentally Responsible Aviation (ERA) program for an N+2 combustor for use in twin-aisle subsonic aircraft engines. Under the N+3 project the ACS combustor was scaled-down for application to small-core N+3 engines for use in single-aisle aircraft. The results show that the NOx and CO emissions characteristics are similar in both the N+2 and N+3 applications. The non-volatile particulate matter (nvPM) emissions trends are similar to CO emissions with an exception at high fuel-air ratio, as inlet air temperature and pressure conditions change from taxi to approach. Three NOx correlation equations are generated to describe theNOx emissions of this combustor. The percentage landing and takeoff (LTO) NOx reduction of the N+3 ACS combustor is between 82% and 89% relative to the ICAO CAEP/6 standard, which meets the NASA N+3 goal of exceeding 80% LTO NOx reduction.

He, Zhuohui J.↗
NASA NTRS2010

Testing and Results of Human Metabolic Simulation Utilizing Ultrasonic Nebulizer Technology for Water Vapor Generation

Life support technology must be evaluated thoroughly before ever being implemented into a functioning design. A major concern during that evaluation is safety. The ability to mimic human metabolic loads allows test engineers to evaluate the effectiveness of new technologies without risking injury to any actual humans. The main function of most life support technologies is the removal of carbon dioxide (CO2) and water (H2O) vapor. As such any good human metabolic simulator (HMS) will mimic the human body s ability to produce these items. Introducing CO2 into a test chamber is a very straightforward process with few unknowns so the focus of this particular new HMS design was on the much more complicated process of introducing known quantities of H2O vapor on command. Past iterations of the HMS have utilized steam which is very hard to keep in vapor phase while transporting and injecting into a test chamber. Also steam adds large quantities of heat to any test chamber, well beyond what an actual human does. For the new HMS an alternative approach to water vapor generation was designed utilizing ultrasonic nebulizers as a method for creating water vapor. Ultrasonic technology allows water to be vibrated into extremely tiny pieces (2-5 microns) and evaporate without requiring additional heating. Doing this process inside the test chamber itself allows H2O vapor generation without the unwanted heat and the challenging process of transporting water vapor. This paper presents the design details as well as results of all initial and final acceptance system testing. Testing of the system was performed at a range of known human metabolic rates in both sea-level and reduced pressure environments. This multitude of test points fully defines the systems capabilities as they relate to actual environmental systems testing.

Stubbe, Matthew↗
NASA NTRS2018

Context Cameras for the Orbiting Carbon Observatory 3 (OCO-3) Instrument

We have developed an adaptable camera platform that takes advantage of screened and qualified commercial off the shelf (COTS) components (CMOS sensor, rad-tolerant microcircuits, lenses) to significantly shorten development time of space-borne visible imaging systems while reducing the overall cost and risk of the development. This modular camera platform is implemented as a suite of two visible-light cameras for the Orbiting Carbon Observatory 3 (OCO-3) instrument at NASA’s Jet Propulsion Laboratory (JPL). The Internal Context Camera (ICC) and External Context Camera (ECC) provide contextual engineering imaging support for the calibration of the OCO-3 instrument, intended to significantly reduce the duration of the mission’s calibration campaign. The OCO-3 mission has taken advantage of the design and qualification work performed by JPL’s Mars 2020 Enhanced Engineering Camera (EECam) team in reusing the qualified COTS CMOS imaging sensor, proven electronic designs, and scalable field-programmable gate array (FPGA) firmware to meet OCO-3’s mission requirements and resource availability. We will be presenting the steps taken by JPL to design, build, and test the Context Cameras for the OCO-3 mission. We will highlight the design deviations from the Mars2020 EECams and discuss the methodology of tailoring the EECam design for the OCO-3 requirements. Camera imaging capabilities, including focal plane and optical performance, will be presented, as well as a summary of the calibration and environmental test results. Finally, we will discuss the potential for future applications for the Context Cameras.

Moore, Douglas↗
NASA NTRS1998

Just the Right Amount of Reinforcement

Lockheed Martin Skunk Works, is taking the next step towards economical low-Earth-orbit (LEO) operations with NASA's X-33 technology demonstrator, that uses composite tanks for liquid hydrogen (LH sub2) fuel storage and structural support, The X-33 is a 53% scale model of the VentureStar single-stage-to-orbit (SSTO) reusable launch vehicle(RLV) projected to orbit payloads at a rate, of $1,000 per pound beginning in 2004 In order to make VentureStar completely reusable and economical engineers are using composite materials throughout the spacecrafts structure. The first test of the design comes in 1999 on the X-33 technology demonstrator. Two of the primary structures that engineers will be evaluating are the carbon fiber/epoxy LH2 fuel tanks. The 29-ft long by 18-ft wide tanks, which fill two-thirds of the X-33's interior, serve a dual purpose carrying fuel and providing structural support to the walls of the spacecraft. Fiber placement makes it possible to build the fuel tanks, large, light and strong enough to satisfy X33's requirements. Lockheed Martin choose the fabrication technology to produce the eight sections of each tank because of fiber placement's ability to handle complex surfaces, speed and repeatability.

Walton, Greg↗
NASA NTRS2021

Risk Reduction of Orion Multi-Purpose Crew Vehicle (MPCV) Program Government-Furnished Equipment for Environmental Control and Life Support (ECLS)

The NASA Engineering and Safety Center (NESC) was requested to conduct technical risk-reduction activities for safety-critical government-furnished environmental control and life support (ECLS) equipment for the Multi-Purpose Crew Vehicle Program. These items include the post-landing anomaly gas monitor, the in-flight anomaly gas monitor, the emergency breathing mask, the 144-hour in-suit survival capability, the portable fire extinguisher, the smoke eater, and the post-landing carbon dioxide control system. This document contains the outcome of the NESC assessment.

Environmental Control and Life Support↗
NASA NTRS2016

Game Changing Development Program - Next Generation Life Support Project: Oxygen Recovery From Carbon Dioxide Using Ion Exchange Membrane Electrolysis Technology

This report summarizes the Phase I research and development work performed during the March 13, 2015 to July 13, 2016 period. The proposal for this work was submitted in response to NASA Research Announcement NNH14ZOA001N, "Space Technology Research, Development, Demonstration, and Infusion 2014 (SpaceTech-REDDI-2014)," Appendix 14GCD-C2 "Game Changing Development Program, Advanced Oxygen Recovery for Spacecraft Life Support Systems Appendix" The Task Agreement for this Phase I work is Document Control Number: GCDP-02-TA-15015. The objective of the Phase I project was to demonstrate in laboratories two Engineering Development Units (EDU) that perform critical functions of the low temperature carbon dioxide electrolysis and the catalytic conversion of carbon monoxide into carbon and carbon dioxide. The low temperature carbon dioxide electrolysis EDU was built by the University of Delaware with Dr. Feng Jiao as the principal investigator in charge of this EDU development (under NASA Contract NNC15CA04C). The carbon monoxide catalytic conversion EDU was built by the NASA Glenn Research Center with Kenneth Burke as the principal investigator and overall project leader for the development of both EDUs. Both EDUs were successfully developed and demonstrated the critical functions for each process. The carbon dioxide electrolysis EDU was delivered to the NASA Johnson Space Center and the carbon monoxide catalytic conversion EDU was delivered to the NASA Marshall Spaceflight Center.

Oxygen Recovery↗
NASA NTRS2003

Fiber Reinforcement Architectures of PMCs on the Hygrothermal-Mechanical Performance for Aeropropulsion Applications

A rigid lightweight sandwich support structure, for the combustor chamber of a new generation liquid propellant rocket engine, was designed and fabricated using Polymer Matric Composite (PMC) facesheet on a Ti honeycomb or Carbon foam core. The facesheet consisted of high stiffness carbon fiber, M40JB, and high temperature Polyimides, such as PMR-11-50 and HFPE-II. Six different fiber architectures; 4HS woven fabric, uni-fabric, woven-uni hybrid, stitched woven fabric, stitched uni-fabric and tri-axial braided structures have been investigated for optimum stiffness-thickness-weight-performance design criteria for the hygrothermal-mechanical propulsion service exposure conditions including rapid heating up to 200 F/sec, maximum operating temperature of 600 F, internal pressure up to 100 psi. An extensive property and performance database including dry-wet mechanical properties at both 25 F and 600 F in various loading modes, thermal and physical properties including blistering onset condition was developed for fiber architecture down-selection and design guidelines. Various optimized process methods including vacuum bag compression molding, solvent assistant RTM (SaRTM), resin film infusion (RFI) were utilized for PMC panel fabrication depending on the architecture type. In the case of stitched woven fabric architecture, the optimal stitch pattern was chosen in terms of stitch density and yarn size, based on both in-plane mechanical properties and blistering performance. Potential reduction of the in-plane properties transverse to the line of stitching was also evaluated. Attempt to correlate the experimental results with theoretical micro-mechanics predictions will be presented.

Shin, Eugene↗
NASA NTRS1992

Regenerative Life Support Systems Test Bed performance - Lettuce crop characterization

Two crops of lettuce (Lactuca sativa cv. Waldmann's Green) were grown in the Regenerative Life Support Systems (RLSS) Test Bed at NASA's Johnson Space Center. The RLSS Test Bed is an atmospherically closed, controlled environment facility for the evaluation of regenerative life support systems using higher plants. The chamber encloses 10.6 m 2 of growth area under cool-white fluorescent lamps. Lettuce was double seeded in 480 pots, each containing about 250 cm 3 of calcined-clay substrate. Each pot was irrigated with half-strength Hoagland's nutrient solution at an average total applied amount of 2.5 and 1.8 liters pot -1 , respectively, over each of the two 30-day crop tests. Average environmental and cultural conditions during both tests were 23°C air temperature, 72% relative humidity, 1000 ppm carbon dioxide (CO 2 ), 16h light/8h dark photoperiod, and 356 μmol m -2 s -1 photosynthetic photon flux. After 30 days from seeding, average yield (g pot -1 ) for the first and second crop tests were 72 and 49 edible (shoot) fresh mass, 3.65 and 2.56 edible dry mass, and 0.44 and 0.45 inedible (root) dry mass, respectively. Averaging over both crop tests, the test bed met the requirements of 2.1 person-days of oxygen production, 2.4 person days of CO 2 removal and 129 person days of potential potable water production. The satisfactory growth of both crops demonstrates the potential of lettuce for air revitalization and water production in a controlled ecological life support system. Differences in crop performance resulting from engineering system effects provides evidence of the resilience of biological systems.

Life support systems↗
NASA NTRS1991

Earth to lunar CELSS evolution

The comprehensive results of human activities on the environment, such as deforestation and ozone depletion, and the natural laws that govern the global environment have yet to be determined. Closed Ecological Life Support Systems (CELSS) research can play an instrumental role in dispelling these mysteries, as well as have the ability to support life in hostile environments, which the Earth one day may become. CELSS conclusions, such as the timescales in which plants fix carbon dioxide (CO2), will be the key to understanding each component and how it affects the ecological balance between plants and animals, the environment, and the biological engines that drive Earth's system. However, to understand how CELSS can be used as an investigative tool, the concept of a CELSS must be clearly defined. A definition of CELSS is given. The evolutionary establishment of a lunar base with a bioregenerative life support system in a Space Station Freedom (SSF) module to support a crew of four for two weeks duration was chosen as the design topic.

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