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NASA NTRS2014

Method for Making a Fuel Cell from a Solid Oxide Monolithic Framework

The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which a thin electrolyte is supported between electrodes of essentially equal thickness. Individual cell units are made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that subsequent to sintering, is made into either an anode or a cathode by means of appropriate solution and thermal treatment means. Each cell unit is assembled by depositing of a thin coating of ion conducting ceramic material upon the side of each of two pieces of tape surface having the smallest pore openings, and then mating the coated surfaces to create an unsintered electrode scaffold pair sandwiching an electrolyte layer. The opposing major outer exposed surfaces of each cell unit is given a thin coating of electrically conductive ceramic, and multiple cell units are stacked, or built up by stacking of individual cell layers, to create an unsintered fuel cell stack. Ceramic or glass edge seals are installed to create flow channels for fuel and air. The cell stack with edge sealants is then sintered into a ceramic monolithic framework. Said solution and thermal treatments means convert the electrode scaffolds into anodes and cathodes. The thin layers of electrically conductive ceramic become the interconnects in the assembled stack.

Cable, Thomas L.↗

NASA NTRS2014

Method for Making a Fuel Cell

The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which an electrolyte layer is supported between porous electrodes. The porous electrodes may be made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze-drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that, subsequent to sintering, is made into either an anode or a cathode. The electrode scaffold comprising the anode includes a layer of liquid metal. The pores of the electrode scaffolds gradually increase in diameter as the layer extends away from the electrolyte layer. As a result of this diameter increase, any forces that would tend to pull the liquid metal away from the electrolyte are reduced while maintaining a diffusion path for the fuel. Advantageously, the fuel cell of the invention may utilize a hydrocarbon fuel without pre-processing to remove sulfur.

Cable, Thomas L.↗

NASA NTRS2020

Probability of Decompression Sickness and Venous Gas Emboli from 49 NASA Hypobaric Chamber Tests with Reference to Exploration Atmosphere

Introduction: Decompression sickness (DCS) is a complex biophysical event; it combines human perception of pain, for instance, and the presence of a gas phase in the tissues. Living tissues are complex and dynamic. Micronuclei and later bubbles may or may not form given what appears to be the same conditions. Even when bubbles grow, symptoms may or may not develop under what appears to be the same conditions. Therefore, at this time it is appropriate to consider DCS as a probabilistic rather than a deterministic event. Methods: Probabilistic models about hypobaric DCS and venous gas emboli (VGE) require a large amount of quality research data, a definition of decompression dose using physical and physiologic variables, and a flexible analytical approach that can quantify the association between each outcome and all covariates of interest (assuming independence between DCS and VGE) and then ultimately be extended to acknowledge dependencies between DCS and VGE. Our DCS and VGE data are from 1,031 hypobaric decompressions from 1983 to 2016. A total of 577 humans participated in 49 hypobaric chamber tests to evaluate denitrogenation procedures used by astronauts in the Space Shuttle and International Space Station programs. We defined decompression dose as the ratio of computed nitrogen tension in a theoretical 360-minute half-time compartment to ambient pressure, which accounts for denitrogenation and exposure pressure as well as explanatory variables such as age, sex, body mass index, and the presence or absence of ambulation as part of exercise at the exposure pressure. A parametric survival model, using a log-logistic distribution, was used to quantify the time to development of DCS, VGE, and Grade IV VGE. Results: Our survival estimates are applicable to simple hypobaric decompressions, such as depressurizations in 5 to 30 minutes to exposure pressures between 4 and 10 pounds per square inch absolute (psia) and after minutes to hours of denitrogenation, either under resting or exercise conditions to accelerated denitrogenation. The regressions are applicable to exposures between 2 to 6 hours and under conditions of ambulation or no ambulation as part of exercise at the test pressure. We estimate that an exposure to 4.3 psia with simulated extravehicular activity (EVA) that includes ambulation after equilibration to the exploration atmosphere at 8.2 psia with a 34% oxygen atmosphere will result in 3.1% DCS (1.8% to 5.2 95% confidence interval), 23.2% VGE (16.7 to 31.2%), and 8.5% Grade IV VGE (4.7 to 14.7%) in equal samples of men and women exposed for 6 hours. Discussion: Probabilistic models for DCS, VGE, and Grade IV VGE can be used to inform those that plan future EVAs. Their applications are useful to quantify the risk of DCS and VGE in astronauts that perform EVAs in low-pressure space suits while in space or while exploring the surfaces of the moon or Mars.

Johnny Conkin↗

NASA NTRSDate not supplied

Human Thermal Assessment of Traverse and Geology Task Iterations During Simulated Lunar Extravehicular Activity

Spacewalks or extravehicular activities (EVA) in microgravity are mentally and physically demanding. Current microgravity EVAs are predominantly focused on upper body tasks on engineered surfaces; however, the introduction of gravity means that crew members during future lunar EVAs will be required to perform tasks that generate full body workloads such as navigating natural lunar terrain while conducting geological sampling. To date, only 12 people have walked on the surface of the Moon resulting in limited knowledge of suited thermal regulation under lunar-relevant physical workloads. To address this gap, a study is underway to focus on spacesuit operations with simulated lunar EVA workloads. This study presents methodology for collecting standard thermal measures during suit testing. In this pilot study, two suited subjects underwent simulated lunar EVAs using the NASA Active Response Gravity Offload System (ARGOS) to simulate the effects of partial gravity. Each lunar EVA, lasting three to five hours, included various metabolically demanding EVA tasks. Subjects donned the NASA Mark III (MK III) space suit and were offloaded to 1/6th G (lunar gravity). A subset task circuit from one of these simulations replicated an EVA traverse to a lunar crater, taking a geological sample, and returning to base. The suited subject walked one 1500 m (0% grade) and three 500 m traverses at three different grades (10, 20, 30%). Between each traverse, subjects performed geology sampling tasks (0 and 10% grade). Thermal measurements included core and skin temperature, liquid cooling garment (LCG) inlet and outlet temperature, and spacesuit gas inlet and outlet temperature and humidity. Compared to baseline core temperature (S1 = 37.07±0.32 °C, S2 = 37.27±0.01 °C) and mean skin temperature (S1 = 32.38±0.34 °C, S2 = 33.62±0.03 °C), after a 1500 m traverse, each suited subject showed an increased core temperature (S1 = 37.23±0.12 °C, S2 = 37.41±0.11°C) and decreased mean skin temperature (S1 = 32.16±0.17 °C, S2 = 31.53±1.15 °C) at a delta LCG temperature (S1 = 1.86±0.24 °C, S2 = 2.20±0.76 °C) and delta suit humidity (S1 = 9.66±1.49 %, S2 = 11.50±1.58 %). Core temperature continued to increase from compounding traverse and geology tasks (S1 = 38.04±0.03 °C, S2 = 38.1±0.02 °C) accompanied by an increase in delta LCG temperature (S1 = 2.24±0.13 °C, S2 = 2.67±0.12 °C) and delta suit humidity (S1 = 28±2.42 %, S2 = 31±2.13 %). Conversely, as the circuit progressed, mean skin temperature continued to decrease due to sustained LCG heat rejection (S1 = 30.08±0.15 °C, S2 = 30.28±0.07 °C). During the simulated EVA circuit core temperature increased to elevated values and remained elevated as heat was retained while mean skin temperature decreased due to peripheral heat offloaded to the LCG. The thermal measures collected during this study provided critical heat loading dynamics during lunar EVA tasks. Including core and skin temperatures along with suited thermal measures provides a standard data collection scheme for human thermal metrics during EVA task management. Data collected in this configuration can be used to build future lunar EVA task circuits and human thermal predictions.

Bradley Hoffmann↗

NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗

NASA NTRS1970

Heat-barrier coatings for combustion chambers

Arc-plasma-sprayed layered coating of graded Inconel and zirconia protects film-coolant ring below injector plate of rocket engine combustion chamber. Interfacial temperature is designed for minimum buildup of stress and to avoid melting of the metal phase in the graded layers.

Carpenter, H. W.↗

NASA NTRS1971

The kinetics of crystallization of molten binary and ternary oxide systems and their application to the origination of high modulus glass fibers

Emphasis on the consideration of glass formation on a kinetic process made it possible to think of glass compositions different from those normally employed in the manufacture of glass fibers. Approximately 450 new glass compositions were prepared and three dozen of these compositions have values for Young's modulus measured on bulk specimens greater than nineteen million pounds per square inch. Of the new glasses about a hundred could be drawn into fibers by mechanical methods at high speeds. The fiber which has a Young's modulus measured on the fiber of 18.6 million pounds per square inch and has been prepared in quantity as a monofilament (to date more than 150 million lineal feet of 0.2 to 0.4 mil fiber have been produced). This fiber has also been successfully incorporated both in epoxy and polyimide matrices. The epoxy resin composite has shown a modulus forty percent better than that achievable using the most common grade of competitive glass fiber, and twenty percent better than that obtainable with the best available grade of competitive glass fiber. Other glass fibers of even higher modulus have been developed.

Bacon, J. F.↗

NASA NTRS1973

Development of seal ring carbon-graphite materials (tasks 8, 9, and 10)

A screening study was conducted to develop improved carbon-graphite materials for use in self-acting seals at air temperatures to 1300 F (704 C). Property measurements on materials prepared during this study have shown that: (1) The mechanical properties of a carbon-graphite material were significantly improved by using a fine milled artificial graphite filler material and including intensive mixing, warm molding, and pitch impregnation in the processing; and (2) the oxidation resistance of a carbon-graphite material was improved by including fine milled boron carbide as an oxidation-inhibiting additive. These techniques were employed to develop a material that has 10 times more oxidation resistance than that of a widely used commercial grade and mechanical properties that approach those of the commercial grade.

Fechter, N. J.↗

NASA NTRS1973

A portable millisecond-integration-time photoelectric photometer.

Portable equipment for recording millisecond-integration-time photoelectric photometric data is described. Digital data are reliably recorded on standard 6.35 mm audio grade magnetic tape via a quadradial audio grade tape deck. The system is designed specifically for recording lunar occulations of stars, but the data recording technique is independent of the data source. Recovery of the data is made via minicomputer.

Mcgraw, J. T.↗

NASA NTRS1973

Study of monopropellants for electrothermal thrusters: Analytical task summary report

The feasibility of operating small thrust level electrothermal thrusters is determined with monopropellants other than MIL-grade hydrazine. The work scope includes analytical study, design and fabrication of demonstration thrusters, and an evaluation test program where monopropellants with freezing points lower than MIL-grade hydrazine are evaluated and characterized to determine their applicability to electrothermal thrusters for spacecraft attitude control. Results of propellant chemistry studies and performance analyses indicated that the most promising candidate monopropellants to be investigated are monomethylhydrazine, Aerozine-50, 77% hydrazine-23% hydrazine azide blend, and TRW formulated mixed hydrazine monopropellant (MHM) consisting of 35% hydrazine-50% monomethylhydrazine-15% ammonia.

Kuenzly, J. D.↗

NASA NTRS1974

Miniature sheathed thermocouples for turbine blade temperature measurement

An investigation was made of sheathed thermocouples for turbine blade temperature measurements. Tests were performed on the Chromel-Alumel sheathed thermocouples with both two-wire and single-wire configurations. Sheath diameters ranged from 0.25 to 0.76 mm, and temperatures ranged from 1080 to 1250 K. Both steady-state and thermal cycling tests were performed for times up to 450 hr. Special-order and commercial-grade thermocouples were tested. The tests showed that special-order single-wire sheathed thermocouples can be obtained that are reliable and accurate with diameters as small as 0.25 mm. However, all samples of 0.25-mm-diameter sheathed commercial-grade two-wire and single-wire thermocouples that were tested showed unacceptable drift rates for long-duration engine testing programs. The drift rates were about 1 percent in 10 hr. A thermocouple drift test is recommended in addition to the normal acceptance tests in order to select reliable miniature sheathed thermocouples for turbine blade applications.

Holanda, R.↗

NASA NTRS1974

Study of monopropellants for electrothermal thrusters: Design and fabrication task summary report

The feasibility of operating small thrust level electrothermal thrusters with monopropellants other than MIL-grade hydrazine was studied. Analytical study, design, and fabrication of demonstration thrusters was performed, and an evaluation test program was initiated to evaluate monopropellants with freezing points lower than MIL-grade hydrazine, and to determine their applicability to electrothermal thrusters for spacecraft attitude control. Five demonstration thrusters were fabricated to determine the feasibility of operation with monomethylhydrazine, Aerozine-50, 77 percent hydrazine-23 percent hydrazine azide, and a mixture of hydrazine monopropellants consisting of 35 percent hydrazine-50 percent monomethylhydrazine-15 percent ammonia. The present thruster is designed to produce a steady-state thrust level of 0.344 N at 1.724 x 1 million N/M sq feed pressure. Vacuum specific impulse goals were set at 1961 N-s/kg steady-state and 1716 N-s/kg pulsed-mode.

Kuenzly, J. D.↗

NASA NTRS1974

Fluorescence and phosphorescence of photomultiplier window materials under electron irradiation

The fluorescence and phosphorescence of photomultiplier window materials under electron irradiation were investigated using a Sr-90/Y-90 beta emitter as the electron source. Spectral emission curves of UV grade, optical grade, and electron-irradiated samples of MGF2 and LiF, CaF2, BaF2, sapphire, fused silica, and UV transmitting glasses were obtained over the spectral range of 200 nm to 650 nm. Fluorescence yields, expressed as the number of counts in a solid angle of 2 pi steradian per 1MeV of incident electron energy deposited, were determined on these materials utilizing photomultiplier tubes with cesium telluride, bialkali, and trialkali (S-20) photocathodes, respectively.

Viehmann, W.↗

NASA NTRS1973

Apollo 16 soils - Grain size analyses and petrography

Soils from South Ray Crater, North Ray Crater, and the interray area of Station 10 have a similar provenance, containing breccia fragments of low to medium metamorphic grade and low light/dark lithic fragment ratios; these appear to be characteristic of the Cayley Formation. The primary difference between soils possibly derived from North Ray and South Ray craters is in the agglutinate content. A soil from Stone Mountain (Station 4) is characterized by breccia fragments of medium to high metamorphic grade and a high light/dark lithic fragment ratio; this soil may be derived from the Descartes Formation. Differences between the selenomorphic units, the Descartes and Cayley formations, may be lithologic as well as structural. The mean grain size varies from 84 to 280 microns, and all of the samples are poorly to very poorly sorted. There appears to be a relation between the sorting, grain size, and agglutinate content, with the finer-grained, better sorted soils containing more than 30% agglutinates. 'Shadowed' soils, collected close to large boulders, are similar in all respects to the 'reference' soils collected at least 5 m from the boulders.

Heiken, G. H.↗

NASA NTRS1973

Pyroxene poikiloblastic rocks from the lunar highlands

The results of detailed petrographic, X-ray, electron microprobe, ion probe, and Ar-40/Ar-39 age studies of pyroxene poikiloblastic breccias, an important lunar highlands lithology, are interpreted to indicate that high grade metamorphic recrystallization occurred over wide regions of the moon at about 4.0 G.y. This metamorphism was probably related to a period of high meteorite influx at that time. The temperatures achieved were highly variable but in some cases were sufficiently intense to cause varying degrees of partial melting of the precursor highlands breccias. A complete spectrum of metamorphic grades from only slight recrystallization to virtually complete melting would be expected in such a model. Such a spectrum is observed in the Apollo 16 rocks.

Bence, A. E.↗

NASA NTRS1973

The distribution in lunar soil of carbon released by pyrolysis

The carbon contents of various lunar soil particle types and sieve fractions of Apollo 15 and 16 samples have been determined by the pyrolysis method. The mineral, glass, and high-grade breccia fragments in the soils examined contain relatively low amounts of carbon (approximately 8, 25, and 25 microg C/g sample respectively in 149-250 micron grains). Most low-grade breccias and all agglutinates examined have high carbon contents (approximately 52 and 80 microg C/g sample respectively), and agglutinate abundance is indicative of the carbon content and maturity of a soil. The distribution of carbon with respect to particle size in mature soils generally reveals a minimum in carbon content at about 100 micron particle diameter. At smaller particle diameters, carbon content is directly proportional to particle surface area and therefore increases with the ratio (surface area)/(particle mass). A model relating the cycle of comminution and aggregation of soil particles to the redistribution of surface implanted carbon is developed.

Desmarais, D. J.↗

NASA NTRS1974

Decompression sickness in simulated Apollo-Soyuz space missions

Apollo-Soyuz docking module atmospheres were evaluated for incidence of decompression sickness in men simulating passage from the Russian spacecraft atmosphere, to the U.S. spacecraft atmosphere, and then to the American space suit pressure. Following 8 hr of 'shirtsleeve' exposure to 31:69::O2:N2 gas breathing mixture, at 10 psia, subjects were 'denitrogenated' for either 30 or 60 min with 100% O2 prior to decompression directly to 3.7 psia suit equivalent while performing exercise at fixed intervals. Five of 21 subjects experienced symptoms of decompression sickness after 60 min of denitrogenation compared to 6 among 20 subjects after 30 min of denitrogenation. A condition of Grade I bends was reported after 60 min of denitrogenation, and 3 of these 5 subjects noted the disappearance of all symptoms of bends at 3.7 psia. After 30 min of denitrogenation, 2 out of 6 subjects developed Grade II bends at 3.7 psia.

Cooke, J. P.↗

NASA NTRS1974

Projection of school district enrollments

The objectives were to provide a better statistical basis for enrollment projections, to attempt to model the school district's enrollment, and to produce a single estimate of enrollment for each grade, grade group, and ethnic group, and for the total by year. Efforts were also made to provide error estimates for the projections, to design a simple, user-oriented computer program for use by school district administrators, and to work with real data from local school districts and aid them in making projections on an experimental basis. The study at Jet Propulsion Laboratory was concerned with projection methodology and production of a generally usable computer program.

Van Dillen, S. L.↗