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All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Ignition and combustion characteristics of metallized propellants

Experimental and analytical investigations focusing on secondary atomization and ignition characteristics of aluminum/liquid hydrocarbon slurry propellants were conducted. Experimental efforts included the application of a laser-based, two-color, forward-scatter technique to simultaneously measure free-flying slurry droplet diameters and velocities for droplet diameters in the range of 10-200 microns. A multi-diffusion flame burner was used to create a high-temperature environment into which a dilute stream of slurry droplets could be introduced. Narrowband measurements of radiant emission were used to determine if ignition of the aluminum in the slurry droplet had occurred. Models of slurry droplet shell formation were applied to aluminum/liquid hydrocarbon propellants and used to ascertain the effects of solids loading and ultimate particle size on the minimum droplet diameter that will permit secondary atomization. For a 60 weight-percent Al slurry, the limiting critical diameter was predicted to be 34.7 microns which is somewhat greater than the 20-25 micron limiting diameters determined in the experiments. A previously developed model of aluminum ignition in a slurry droplet was applied to the present experiments and found to predict ignition times in reasonable agreement with experimental measurements. A model was also developed that predicts the mechanical stress in the droplet shell and a parametric study was conducted. A one-dimensional model of a slurry-fueled rocket combustion chamber was developed. This model includes the processes of liquid hydrocarbon burnout, secondary atomization, aluminum ignition, and aluminum combustion. Also included is a model for radiant heat transfer from the hot aluminum oxide particles to the chamber walls. Exercising this model shows that only a modest amount of secondary atomization is required to reduce residence times for aluminum burnout, and thereby maintain relatively short chamber lengths. The model also predicts radiant heat transfer losses to the walls to be only approximately 3 percent of the fuel energy supplied. Additional work is required to determine the effects of secondary atomization on two-phase losses in the nozzle.

Turns, Stephen R.↗
NASA NTRS2016

Hall Thruster Thermal Modeling and Test Data Correlation

HERMeS - Hall Effect Rocket with Magnetic Shielding. Developed through a joint effort by NASA/GRC and the Jet Propulsion Laboratory (JPL). Design goals: High power (12.5 kW) high Isp (3000 sec), high efficiency (> 60%), high throughput (10,000 kg), reduced plasma erosion and increased life (5 yrs) to support Asteroid Redirect Robotic Mission (ARRM). Further details see "Performance, Facility Pressure Effects and Stability Characterization Tests of NASAs HERMeS Thruster" by H. Kamhawi and team. Hall Thrusters (HT) inherently operate at elevated temperatures approx. 600 C (or more). Due to electric magnetic (E x B) fields used to ionize and accelerate propellant gas particles (i.e., plasma). Cooling is largely limited to radiation in vacuum environment.Thus the hardware components must withstand large start-up delta-T's. HT's are constructed of multiple materials; assorted metals, non-metals and ceramics for their required electrical and magnetic properties. To mitigate thermal stresses HT design must accommodate the differential thermal growth from a wide range of material Coef. of Thermal Expansion (CTEs). Prohibiting the use of some bolted/torqued interfaces.Commonly use spring loaded interfaces, particularly at the metal-to-ceramic interfaces to allow for slippage.However most component interfaces must also effectively conduct heat to the external surfaces for dissipation by radiation.Thus contact pressure and area are important.

Model↗
NASA NTRS2011

An Active Broad Area Cooling Model of a Cryogenic Propellant Tank with a Single Stage Reverse Turbo-Brayton Cycle Cryocooler

As focus shifts towards long-duration space exploration missions, an increased interest in active thermal control of cryogenic propellants to achieve zero boil-off of cryogens has emerged. An active thermal control concept of considerable merit is the integration of a broad area cooling system for a cryogenic propellant tank with a combined cryocooler and circulator system that can be used to reduce or even eliminate liquid cryogen boil-off. One prospective cryocooler and circulator combination is the reverse turbo-Brayton cycle cryocooler. This system is unique in that it has the ability to both cool and circulate the coolant gas efficiently in the same loop as the broad area cooling lines, allowing for a single cooling gas loop, with the primary heat rejection occurring by way of a radiator and/or aftercooler. Currently few modeling tools exist that can size and characterize an integrated reverse turbo-Brayton cycle cryocooler in combination with a broad area cooling design. This paper addresses efforts to create such a tool to assist in gaining a broader understanding of these systems, and investigate their performance in potential space missions. The model uses conventional engineering and thermodynamic relationships to predict the preliminary design parameters, including input power requirements, pressure drops, flow rate, cycle performance, cooling lift, broad area cooler line sizing, and component operating temperatures and pressures given the cooling load operating temperature, heat rejection temperature, compressor inlet pressure, compressor rotational speed, and cryogenic tank geometry. In addition, the model allows for the preliminary design analysis of the broad area cooling tubing, to determine the effect of tube sizing on the reverse turbo-Brayton cycle system performance. At the time this paper was written, the model was verified to match existing theoretical documentation within a reasonable margin. While further experimental data is needed for full validation, this tool has already made significant steps towards giving a clearer understanding of the performance of a reverse turbo-Brayton cycle cryocooler integrated with broad area cooling technology for zero boil-off active thermal control.

Guzik, Monica C.↗
NASA NTRS2018

A Common Probe Design for Multiple Planetary Destinations

Atmospheric probes have been successfully flown to planets and moons in the solar system to conduct in situ measurements. They include the Pioneer Venus multi-probes, the Galileo Jupiter probe, and Huygens probe. Probe mission concepts to five destinations, including Venus, Jupiter, Saturn, Uranus, and Neptune, have all utilized similar-shaped aeroshells and concept of operations, namely a 45-degree sphere cone shape with high density heatshield material and parachute system for extracting the descent vehicle from the aeroshell. Each concept designed its probe to meet specific mission requirements and to optimize mass, volume, and cost. At the 2017 International Planetary Probe Workshop (IPPW), NASA Headquarters postulated that a common aeroshell design could be used successfully for multiple destinations and missions. This "common probe" design could even be assembled with multiple copies, properly stored, and made available for future NASA missions, potentially realizing savings in cost and schedule and reducing the risk of losing technologies and skills difficult to sustain over decades. Thus the NASA Planetary Science Division funded a study to investigate whether a common probe design could meet most, if not all, mission needs to the five planetary destinations with extreme entry environments. The Common Probe study involved four NASA Centers and addressed these issues, including constraints and inefficiencies that occur in specifying a common design. Study methodology: First, a notional payload of instruments for each destination was defined based on priority measurements from the Planetary Science Decadal Survey. Steep and shallow entry flight path angles (EFPA) were defined for each planet based on qualification and operational g-load limits for current, state-of-the-art instruments. Interplanetary trajectories were then identified for a bounding range of EFPA. Next, 3-degrees-of-freedom simulations for entry trajectories were run using the entry state vectors from the interplanetary trajectories. Aeroheating correlations were used to generate stagnation point convective and radiative heat flux profiles for several aeroshell shapes and entry masses. High fidelity thermal response models for various Thermal Protection System (TPS) materials were used to size stagnation-point thicknesses, with margins based on previous studies. Backshell TPS masses were assumed based on scaled heat fluxes from the heatshield and also from previous mission concepts. Presentation: We will present an overview of the study scope, highlights of the trade studies and design driver analyses, and the final recommendations of a common probe design and assembly. We will also indicate limitations that the common probe design may have for the different destinations. Finally, recommended qualification approaches for missions will be presented.

Hwang, H. H.↗
NASA NTRS2009

Development, Testing, and Failure Mechanisms of a Replicative Ice Phase Change Material Heat Exchanger

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as Low Earth Orbit (LEO) and Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM s have over evaporators in this scenario is that they do not use a consumable. Wax PCM units have been baselined for the Orion thermal control system and also provide risk mitigation for the Altair Lander. However, the use of water as a PCM has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. An ice PCM heat exchanger that replicates the thermal energy storage capacity of an existing wax PCM unit was fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion are investigated. This paper presents the results to date of this investigation.

Leimkuehler, Thomas O.↗
NASA NTRS2010

Development, Testing, and Failure Mechanisms of a Replicative Ice Phase Change Material Heat Exchanger

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as Low Earth Orbit (LEO) and Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM's have over evaporators in this scenario is that they do not use a consumable. Wax PCM units have been baselined for the Orion thermal control system and also provide risk mitigation for the Altair Lander. However, the use of water as a PCM has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. An ice PCM heat exchanger that replicates the thermal energy storage capacity of an existing wax PCM unit was fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion are investigated. This paper presents the results to date of this investigation. Nomenclature

Leimkuehler, Thomas O.↗
NASA NTRS2003

Mechanical Testing of PMCs under Simulated Rapid Heat-Up Propulsion Environments: In-Plane Compressive Behavior - II

Carbon fiber thermoset polymer matrix composites (PMC) with high temperature polyimide based in-situ polymerized monomer reactant (PMR) resin has been used for some time in applications which can see temperatures up to 550 F. Currently, graphite fiber PMR based composites are used in several aircraft engine components including the outer bypass duct for the GE F-404, exit flaps for the P&W F-100-229, and the core cowl for the GE/Snecma CF6-80A3. Newer formulations, including PMR-II-50 are being investigated as potential weight reduction replacements of various metallic components in next generation high performance propulsion rocket engines that can see temperatures which exceed 550 F. Extensive FEM thermal modeling indicates that these components are exposed to rapid heat-up rates (up to -200 F/sec) and to a maximum temperature of around 600 F. Even though the predicted maximum part temperatures were within the capability of PW-II-50, the rapid heat-up causes significant through-thickness thermal gradients in the composite part and even more unstable states when combined with moisture. Designing composite parts for such extreme service environments will require accurate measurement of intrinsic and transient mechanical properties and the hygrothermal performance of these materials under more realistic use conditions. The mechanical properties of polymers degrade when exposed to elevated temperatures even in the absence of gaseous oxygen. Accurate mechanical characterization of the material is necessary in order to reduce system weight while providing sufficient factors of safety. Historically, the testing of PMCs at elevated temperatures has been plagued by the antagonism between two factors. First, moisture has been shown to profoundly affect the mechanical response of these materials at temperatures above their glass transition temperature while concurrently lowering the material's Tg. Moisture phenomena is due to one or a combination of three effects, i.e., plastization of polymeric material by water, the internal pressure generated by the volatilization of water at elevated temperatures, and hydrolytic chemical decomposition. However, moisture is lost from the material at increasing rates as temperature increases. Second, because PMCs are good thermal insulators, when they are externally heated at even mild rates large thermal gradients can develop within the material. At temperatures where a material property changes rapidly with temperature the presence of a large thermal gradient is unacceptable for intrinsic property characterization purposes. Therefore, long hold times are required to establish isothermal conditions. However, in the service environments high-heating-rates, high temperatures, high-loading rates are simultaneous present along with residual moisture. In order to capture the effects of moisture on the material, holding at- temperature until isothermal conditions are reached is unacceptable particularly in materials with small physical dimensions. Thus, the effects due to moisture on the composite's mechanical characteristics, ie., their so-called analog response, may be instructive. One approach employed in this program was rapid heat-up (approx. 200 F/sec.) and loading of both dry and wet in-plane compressive specimens to examine the effects of moisture on this resin dominated mechanical property of the material.

Stokes, Eric H.↗
NASA NTRSDate not supplied

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at up to 6,800 rpm. The first non-rotating tests of the fully assembled HEMM cryocooler have been completed, and initial testing has yielded a no-load temperature of 112 K. A small helium leak into the vacuum system has been identified as the major bottleneck to performance, and based on measurements with the motor turned off there is an observed vacuum-side heat leak of approximately 30 W at 115 K. Immediate next steps for testing are to locate and mitigate the apparent helium leaks into the vacuum chamber. Thus far, compressor performance and the apparent heat lift after correcting for the heat leak are on par with expectations.

Electrified Aircraft Propulsion↗
NASA NTRS2010

Possible Influences of Air Pollution, Dust and Sandstorms on the Indian Monsoon

In Asian monsoon countries, such as China and India, human health and safety problems caused by air pollution are becoming increasingly serious, due to the increased loading of atmospheric pollutants from waste gas emissions and from rising energy demand associated with the rapid pace of industrialization and modernization. Meanwhile, uneven distribution of monsoon rain associated with flash floods or prolonged drought, has caused major loss of human life and damage to crops and.property with devastating societal impacts. Historically, air-pollution and monsoons research are treated as separate problems. However recent studies have suggested that the two problems may be intrinsically linked and need to be studied jointly. Fundamentally, aerosols can affect precipitation through radiative effects cif suspended particles in the atmosphere (direct effect) and/or by interfering and changing: the cloud and precipitation formation processes (indirect effect). Based on their optical properties, aerosols can be classified into two types.: those that absorb solar radiation, and those that do not. Both types of aerosols scatter sunlight and reduce the amount of solar radiation from reaching the Earth's surface, causing it to cool. The surface cooling increases atmospheric stability and reduces convection potential, Absorbing aerosols, however, in addition to cooling the surface, can heat the atmosphere. The heating of the atmosphere may reduce the amount of low clouds by increased evaporation in cloud drops. The heating, however, may induce rising motion, enhance low-level moisture, convergence and, hence, increases rainfall, The latent heating from enhanced rainfall may excite feedback processes in the large-scale circulation, further amplify.the initial response to aerosol heating and producing more rain. Additionally, aerosols can increase the concentration of cloud condensation nuclei (CCN), increase cloud amount and decrease coalescence and collision rates, leading to reduced precipitation. However, in the presence of increasing moist and warm air, the reduced coalescence/collision may lead to supercooled drops at higher altitudes where ice precipitation falls and melts. The latent heat release from freezing aloft and melting below implies greater upward heat transport in polluted clouds and invigorate deep convection. In this way, aerosols may lead to increased local convection. Hence, depending on the ambient large-scale conditions and dynamical feedback processes, aerosols' effect on precipitation can be positive, negative or mixed. In the Asian monsoon and adjacent regions, the aerosol forcing and responses of the water cycle are even more complex, Both direct and indirect effects may take place locally and simultaneously, interacting with each other. in addition to local effects, monsoon rainfall may be affected by aerosols transported from other regions and intensified through large-scale circulation and moisture feedback. Thus, dust transported by the large-scale circulation from the adjacent deserts to northern India may affect rainfall over the Bay of Bengal; sulphate and black carbon front industrial pollution in central, southern China and northern India may affect the rainfall regime over the Korean peninsula and Japan; organic and black carbon front biomass burning from Indo-China may modulate the pre-monsoon rainfall regime over southern China and coastal regions, contributing to variability in differential heating and cooling of the atmosphere and to the land-sea thermal contrast. During the pre-monsoon season and monsoon breaks, it has been suggested that radiative forcing by absorbing aerosols have nearly the same order of magnitude as the forcing due to latent heating from convection and surface fluxes. The magnitude of the total aerosol radiative cooling due to sulphates and soot is of the order of 20-40 W/m2 over the Asian monsoon land region in the pre-monsoon season, compared to about 1-2 W/m2 for global warng. However, the combined forcing at the surface and in the atmosphere, including all species. if aerosols, and details of aerosol mixing, and impacts on the energy and water cycles in the monsoon land regions, are not well known.

Lau, William K. M.↗
NASA NTRS2005

Resistively-Heated Microlith-based Adsorber for Carbon Dioxide and Trace Contaminant Removal

An integrated sorber-based Trace Contaminant Control System (TCCS) and Carbon Dioxide Removal Assembly (CDRA) prototype was designed, fabricated and tested. It corresponds to a 7-person load. Performance over several adsorption/regeneration cycles was examined. Vacuum regenerations at effective time/temperature conditions, and estimated power requirements were experimentally verified for the combined CO2/trace contaminant removal prototype. The current paper details the design and performance of this prototype during initial testing at CO2 and trace contaminant concentrations in the existing CDRA, downstream of the drier. Additional long-term performance characterization is planned at NASA. Potential system design options permitting associated weight, volume savings and logistic benefits, especially as relevant for long-duration space flight, are reviewed. The technology consisted of a sorption bed with sorbent- coated metal meshes, trademarked and patented as Microlith by Precision Combustion, Inc. (PCI). By contrast the current CO2 removal system on the International Space Station employs pellet beds. Preliminary bench scale performance data (without direct resistive heating) for simultaneous CO2 and trace contaminant removal was reviewed in SAE 2004-01-2442. In the prototype, the meshes were directly electrically heated for rapid response and accurate temperature control. This allowed regeneration via resistive heating with the potential for shorter regeneration times, reduced power requirement, and net energy savings vs. conventional systems. A novel flow arrangement, for removing both CO2 and trace contaminants within the same bed, was demonstrated. Thus, the need for a separate trace contaminant unit was eliminated resulting in an opportunity for significant weight savings. Unlike the current disposable charcoal bed, zeolites for trace contaminant removal are amenable to periodic regeneration.

Roychoudhury, S.↗
NASA NTRS2014

Development and Experimental Evaluation of Passive Fuel Cell Thermal Control

To provide uniform cooling for a fuel cell stack, a cooling plate concept was evaluated. This concept utilized thin cooling plates to extract heat from the interior of a fuel cell stack and move this heat to a cooling manifold where it can be transferred to an external cooling fluid. The advantages of this cooling approach include a reduced number of ancillary components and the ability to directly utilize an external cooling fluid loop for cooling the fuel cell stack. A number of different types of cooling plates and manifolds were developed. The cooling plates consisted of two main types; a plate based on thermopyrolytic graphite (TPG) and a planar (or flat plate) heat pipe. The plates, along with solid metal control samples, were tested for both thermal and electrical conductivity. To transfer heat from the cooling plates to the cooling fluid, a number of manifold designs utilizing various materials were devised, constructed, and tested. A key aspect of the manifold was that it had to be electrically nonconductive so it would not short out the fuel cell stack during operation. Different manifold and cooling plate configurations were tested in a vacuum chamber to minimize convective heat losses. Cooling plates were placed in the grooves within the manifolds and heated with surface-mounted electric pad heaters. The plate temperature and its thermal distribution were recorded for all tested combinations of manifold cooling flow rates and heater power loads. This testing simulated the performance of the cooling plates and manifold within an operational fuel cell stack. Different types of control valves and control schemes were tested and evaluated based on their ability to maintain a constant temperature of the cooling plates. The control valves regulated the cooling fluid flow through the manifold, thereby controlling the heat flow to the cooling fluid. Through this work, a cooling plate and manifold system was developed that could maintain the cooling plates within a minimal temperature band with negligible thermal gradients over power profiles that would be experienced within an operating fuel cell stack.

Fuel Cells↗
NASA NTRS2015

A Morphing Radiator for High-Turndown Thermal Control of Crewed Space Exploration Vehicles

Spacecraft designed for missions beyond low earth orbit (LEO) face a difficult thermal control challenge, particularly in the case of crewed vehicles where the thermal control system (TCS) must maintain a relatively constant internal environment temperature despite a vastly varying external thermal environment and despite heat rejection needs that are contrary to the potential of the environment. A thermal control system is in other words required to reject a higher heat load to warm environments and a lower heat load to cold environments, necessitating a quite high turndown ratio. A modern thermal control system is capable of a turndown ratio of on the order of 12:1, but for crew safety and environment compatibility these are massive multi-loop fluid systems. This paper discusses the analysis of a unique radiator design which employs the behavior of shape memory alloys (SMA) to vary the turndown of, and thus enable, a single-loop vehicle thermal control system for space exploration vehicles. This design, a morphing radiator, varies its shape in response to facesheet temperature to control view of space and primary surface emissivity. Because temperature dependence is inherent to SMA behavior, the design requires no accommodation for control, instrumentation, nor power supply in order to operate. Thermal and radiation modeling of the morphing radiator predict a turndown ranging from 11.9:1 to 35:1 independent of TCS configuration. Stress and deformation analyses predict the desired morphing behavior of the concept. A system level mass analysis shows that by enabling a single loop architecture this design could reduce the TCS mass by between 139 kg and 225 kg. The concept is demonstrated in proof-of-concept benchtop tests.

Cognata, Thomas J.↗
NASA NTRS1998

Power Management and Distribution System Developed for Thermionic Power Converters

A spacecraft solar, bimodal system combines propulsion and power generation into a single integrated system. An Integrated Solar Upper Stage (ISUS) provides orbital transfer capabilities, power generation for payloads, and onboard propulsion to the spacecraft. A key benefit of a bimodal system is a greater payload-to-spacecraft mass ratio resulting in lower launch vehicle requirements. Scaling down to smaller launch vehicles increases space access by reducing overall mission cost. NASA has joined efforts with the Air Force Phillips Laboratory to develop enabling technologies for such a system. The NASA/Air Force bimodal concept uses solar concentrators to focus energy into an integrated power plant. This power plant consists of a graphite core that stores thermal energy within a cavity. An array of thermionic converters encircles the graphite cavity and provides electrical energy conversion functions. During the power generation phase of the bimodal system, the thermionic converters are exposed to the heated cavity and convert the thermal energy to electricity. Near-term efforts of the ISUS bimodal program are focused on a ground demonstration of key technologies in order to proceed to a full space flight test. Thermionic power generation is one key technology of the bimodal concept. Thermionic power converters impose unique operating requirements upon a power management and distribution (PMAD) system design. Single thermionic converters supply large currents at very low voltages. Operating voltages can vary over a range of up to 3 to 1 as a function of operating temperature. Most spacecraft loads require regulated 28-volts direct-current (Vdc) power. A combination of series-connected converters and powerprocessing boosters is required to deliver power to the spacecraft's payloads at this level.

Baez, Anastacio N.↗
NASA NTRS2012

Advanced Lithium Ion Venus Explorer (ALIVE)

The COncurrent Multidisciplinary Preliminary Assessment of Space Systems (COMPASS) Team partnered with the Applied Research Laboratory to perform a NASA Innovative Advanced Concepts (NIAC) Program study to evaluate chemical based power systems for keeping a Venus lander alive (power and cooling) and functional for a period of days. The mission class targeted was either a Discovery ($500M) or New Frontiers ($750M to $780M) class mission. Historic Soviet Venus landers have only lasted on the order of 2 hours in the extreme Venus environment:temperatures of 460 degrees Centigrade and pressures of 93 bar. Longer duration missions have been studied using plutonium powered systems to operate and cool landers for up to a year. However, the plutonium load is very large. This NIAC study sought to still provide power and cooling but without the plutonium. Batteries are far too heavy but a system which uses the atmosphere (primarily carbon dioxide) and on on-board fuel to power a power generation and cooling system was sought. The resuling design was the Advanced Long-Life Lander Investigating the Venus Environment (ALIVE) Spacecraft (S/C) which burns lithium (Li) with the CO2 atmosphere to heat a Duplex Stirling to power and cool the lander for a 5-day duration (until the Li is exhausted). While it does not last years a chemical powered system surviving days eliminates the cost associated with utilizing a flyby relay S/C and allows a continuous low data rate direct to earth (DTE) link in this instance from the Ovda Regio of Venus. The five-day collection time provided by the chemical power systems also enables science personnel on earth to interact and retarget science - something not possible with an approximately 2-hour spacecraft lifetime. It also allows for contingency operations directed by the ground (reduced risk). The science package was based on that envisioned by the Venus Intrepid Tessera Lander (VITaL) Decadal Survey Study. The Li Burner within the long duration power system creates approximately 14000 W of heat. This 1300 degree Centigrade heat using Li in the bottom "ballast" tank is melted to liquid by the Venus temperature, drawn into a furnace by a wick and burned with atmospheric CO2. The Li carbonate exhaust is liquid at 1300 degrees Centigrade and being denser than Li drains into the the Li tank and solidifies. Since the exhaust product is a dense liquid no "chimney" is required which conserves the heat for the stirling power convertor. The Duplex Stirling provides about 300 W of power and removes about 300 W of heat from the avionics and heat that leaks into the 1-bar-insulated payload pressure vessel kept at 25 degrees Centigrade. The Na K radiator is run to the top of the drag flap.The ALIVE vehicle is carried to Venus via an Atlas 411 launch vehicle (LV) with a C3 of 7 km2/s2. An Aeroshell, derived from the Genesis mission, enables a direct entry into the atmosphere of Venus (-10 degrees Centigrade, 40 g max) and 6 m/s for landing (44 g) using a drag ring. For surface science and communication, a 100 WRF (WebEx Recording Format), X-Band 0.6-meter pointable DTE (Direct-to-Earth) antenna provides 2 kbps (kilobits per second) to DSN (Deep-Space Network) 34-meter antenna clusters.Table 1.1 summarizes the top-level details of each subsystem that was incorporated into the design. Cost estimates of the ALIVE mission show it at approximately $760M which puts it into the New Frontiers class.The ALIVE landed duration is only limited by the amount of Li which can be carried by the lander. Further studies are needed to investigate how additional mass can be carried, perhaps by a larger launcher and larger aeroshell.

Exploration↗
NASA NTRSDate not supplied

Recent Advances in the U.S. in Ablative TPS for In-situ Exploration of Giant Planets

The Decadal Survey report released [1] prioritizes Uranus as the highest priority Flagship class mission to be explored with an orbiter and a probe and it also recommended Saturn Probe under New Frontiers mission class. Thermal protection system (TPS) is essential for Uranus and Saturn probe missions. The two cardinal requirements are that it must be fail-safe and yet be mass efficient. The Decadal Survey report also pointed out the readiness of heatshield for extreme entry environment technology (HEEET) at TRL 6 for probe missions at Gas Giants. HEEET relies on 3-D weaving and is shown to be a robust and mass efficient TPS through ground testing and analysis. HEEET was matured to TRL 6 in 2019. HEEET was reported at the Ice Giant Workshop in 2019 at Marseille. Since 2019, significant advances have been made primarily because of Mars Sample Return (MSR) mission. MSR baselined 3-D Woven TPS as its heatshield for the earth entry system. MSR earth entry system (EES) requirements and the resulting heatshield/TPS requirements are most stringent of all entry missions. This is a result of backward contamination protection which classifies MSR as a “restricted class 5” mission to safeguard the accidental release of potentially hazardous Mars Sample into Earth’s atmosphere. Complex requirements for the heatshield start with micro-meteor impact tolerance followed by the requirement for steep entry to minimize the size of the impact footprint which results in extreme heating. The heatshield is part of the impact attenuation system. The EES architecture does not use a parachute and is designed to tolerate impact loads. Hence heatshield TPS selection and design becomes one of the key challenges. After completion of the HEEET technology maturation in 2019, IRAD efforts focused on assessing the 3-D Woven family of TPS to MSR EES. After nearly two years of evaluation of alternate TPS such as carbon phenolic, C-C hot structure, PICA, and 3-D woven family of TPS, a single layer 3-D woven TPS derived from the dual-layer HEEET was down selected and is currently the baseline. A new loom capable of weaving the single-layer 3-D woven preform at 80” wide has been designed, assembled and is currently on the verge of weaving the MSR EES TPS. During the HEEET maturation and the follow-on development, the single-layer TPS has been tested at extreme heating conditions. As a result, single layer TPS was recommended and evaluated during the Planetary Mission Concept Studies funded by NASA in preparation for the Decadal committee. In addition, in anticipation of Saturn mission proposals, single layer was evaluated as well. Aerocapture can reduce the trip time, also allow bigger payload fraction and in addition, it allows for the possibility of probe delivery once the spacecraft is in orbit. This can lead to obtaining both in-situ data as well as data from orbit simultaneously. Since Aerocapture depletes energy/velocity, probe delivery from orbit reduces the demand on TPS. Aerocapture was mentioned in the Decadal Study report as ready for implementation, but due to perceived risk it is not adopted by the mission designers. Establishing TPS readiness for aerocapture missions will be addressed. Going one step beyond aerocapture is aerogravity assist if fast return is the goal. Recent studies [4] looked at aerogravity assist and the TPS readiness. This talk will highlight both aerocapture and aerogravity assist from a TPS perspective. The main objective of this proposed talk is to present a comprehensive picture of the SOA TPS technology including recent developments. The talk will highlight advances in manufacturing, results from the Decadal White Papers, PMCS and other studies, and aerocapture and aerogravity assist that could play a role in the near or far term in-situ exploration.

E. Venkatapathy↗
NASA NTRS2014

A Morphing Radiator for High-Turndown Thermal Control of Crewed Space Exploration Vehicles

Spacecraft designed for missions beyond low earth orbit (LEO) face a difficult thermal control challenge, particularly in the case of crewed vehicles where the thermal control system (TCS) must maintain a relatively constant internal environment temperature despite a vastly varying external thermal environment and despite heat rejection needs that are contrary to the potential of the environment. A thermal control system may be required to reject a higher heat load to warm environments and a lower heat load to cold environments, necessitating a relatively high turndown ratio. A modern thermal control system is capable of a turndown ratio of on the order of 12:1, but crew safety and environment compatibility have constrained these solutions to massive multi-loop fluid systems. This paper discusses the analysis of a unique radiator design that employs the behavior of shape memory alloys (SMAs) to vary the turndown of, and thus enable, a single-loop vehicle thermal control system for space exploration vehicles. This design, a morphing radiator, varies its shape in response to facesheet temperature to control view of space and primary surface emissivity. Because temperature dependence is inherent to SMA behavior, the design requires no accommodation for control, instrumentation, or power supply in order to operate. Thermal and radiation modeling of the morphing radiator predict a turndown ranging from 11.9:1 to 35:1 independent of TCS configuration. Coupled thermal-stress analyses predict that the desired morphing behavior of the concept is attainable. A system level mass analysis shows that by enabling a single loop architecture this design could reduce the TCS mass by between 139 kg and 225 kg. The concept has been demonstrated in proof-of-concept benchtop tests.

Cognata, Thomas J.↗
NASA NTRS2019

Investigating Additively Manufactured 17-4 PH for Structural Applications

17-4 is used regularly to manufacture force transducers particularly for wind tunnel testing. Such applications place demanding structural requirements on the transducers with static safety factors of 1.5 common and the potential for additional dynamic loads. Additive manufacturing (AM) of transducers is very appealing because of significant potential cost and time savings as well as increased design flexibility. This study looks at the processing of 17-4 powder using selective laser melting by two different facilities using their own best practices. Hot isostatic pressing (HIP) is used by both facilities as part of the thermomechanical processing following printing to explore whether it can improve the consistency of mechanical properties. Results revealed that HIP reduced average porosity of 17-4 parts and that the yield strength of parts following solutionization and aging met wrought material property targets. Strain to failure of one of the facilities parts was less than 5% compared to greater than 9% for the other facility. Inspection of failure surfaces revealed this discrepancy could be attributed to pores (2-4% area fraction) on the failure surface of the low ductility parts. Phase content varied between the facilities with one facility producing fully martensitic parts and the other containing some retained austenite. The phase content of the starting powder and a slower than air cooling rate following the final heat treatment above the austenite eutectoid temperature are likely sources of the retained austenite. Taken together these results suggest that the current state of the art in AM 17-4 processing is sufficient for many NASA force measurement applications, but that attention is required at each stage of processing to assure desired mechanical properties.

Burns, Devin E.↗
NASA NTRS1994

Cabin fuselage structural design with engine installation and control system

Design requirements for the cabin, cabin system, flight controls, engine installation, and wing-fuselage interface that provide adequate interior volume for occupant seating, cabin ingress and egress, and safety are presented. The fuselage structure must be sufficient to meet the loadings specified in the appropriate sections of Federal Aviation Regulation Part 23. The critical structure must provide a safe life of 10(exp 6) load cycles and 10,000 operational mission cycles. The cabin seating and controls must provide adjustment to account for various pilot physiques and to aid in maintenance and operation of the aircraft. Seats and doors shall not bind or lockup under normal operation. Cabin systems such as heating and ventilation, electrical, lighting, intercom, and avionics must be included in the design. The control system will consist of ailerons, elevator, and rudders. The system must provide required deflections with a combination of push rods, bell cranks, pulleys, and linkages. The system will be free from slack and provide smooth operation without binding. Environmental considerations include variations in temperature and atmospheric pressure, protection against sand, dust, rain, humidity, ice, snow, salt/fog atmosphere, wind and gusts, and shock and vibration. The following design goals were set to meet the requirements of the statement of work: safety, performance, manufacturing and cost. To prevent the engine from penetrating the passenger area in the event of a crash was the primary safety concern. Weight and the fuselage aerodynamics were the primary performance concerns. Commonality and ease of manufacturing were major considerations to reduce cost.

Balakrishnan, Tanapaal↗