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NASA NTRS1995

Functional Testing of the Space Station Plasma Contactor

A plasma contactor system has been baselined for the International Space Station Alpha (ISSA) to control the electrical potentials of surfaces to eliminate/mitigate damaging interactions with the space environment. The system represents a dual-use technology which is a direct outgrowth of the NASA electric propulsion program and, in particular, the technology development effort on ion thruster systems. The plasma contactor subsystems include a hollow cathode assembly, a power electronics unit, and an expellant management unit. Under a pre-flight development program these subsystems are being developed to the level of maturity appropriate for transfer to U.S. industry for final development. Development efforts for the hollow cathode assembly include design selection and refinement, validating its required lifetime, and quantifying the cathode performance and interface specifications. To date, cathode components have demonstrated over 10,000 hours lifetime, and a hollow cathode assembly has demonstrated over 3,000 ignitions. Additionally, preliminary integration testing of a hollow cathode assembly with a breadboard power electronics unit has been completed. This paper discusses test results and the development status of the plasma contactor subsystems for ISSA, and in particular, the hollow cathode assembly.

Patterson, Michael J.↗

NASA NTRS1995

The TMI regenerable solid oxide fuel cell

Energy storage and production in space requires rugged, reliable hardware which minimizes weight, volume, and maintenance while maximizing power output and usable energy storage. These systems generally consist of photovoltaic solar arrays which operate during sunlight cycles to provide system power and regenerate fuel (hydrogen) via water electrolysis; during dark cycles, hydrogen is converted by the fuel cell into system. The currently preferred configuration uses two separate systems (fuel cell and electrolyzer) in conjunction with photovoltaic cells. Fuel cell/electrolyzer system simplicity, reliability, and power-to-weight and power-to-volume ratios could be greatly improved if both power production (fuel cell) and power storage (electrolysis) functions can be integrated into a single unit. The Technology Management, Inc. (TMI), solid oxide fuel cell-based system offers the opportunity to both integrate fuel cell and electrolyzer functions into one unit and potentially simplify system requirements. Based an the TMI solid oxide fuel cell (SOPC) technology, the TMI integrated fuel cell/electrolyzer utilizes innovative gas storage and operational concepts and operates like a rechargeable 'hydrogen-oxygen battery'. Preliminary research has been completed on improved H2/H2O electrode (SOFC anode/electrolyzer cathode) materials for solid oxide, regenerative fuel cells. Improved H2/H2O electrode materials showed improved cell performance in both fuel cell and electrolysis modes in reversible cell tests. ln reversible fuel cell/electrolyzer mode, regenerative fuel cell efficiencies (ratio of power out (fuel cell mode) to power in (electrolyzer model)) improved from 50 percent (using conventional electrode materials) to over 80 percent. The new materials will allow the TMI SOFC system to operate as both the electrolyzer and fuel cell in a single unit. Preliminary system designs have also been developed which indicate the technical feasibility of using the TMI SOFC technology for space applications with high energy storage efficiencies and high specific energy. Development of small space systems would also have potential dual-use, terrestrial applications.

Cable, Thomas L.↗

NASA NTRS1995

Monolithically interconnected GaAs solar cells: A new interconnection technology for high voltage solar cell output

Photovoltaic linear concentrator arrays can benefit from high performance solar cell technologies being developed at AstroPower. Specifically, these are the integration of thin GaAs solar cell and epitaxial lateral overgrowth technologies with the application of monolithically interconnected solar cell (MISC) techniques. This MISC array has several advantages which make it ideal for space concentrator systems. These are high system voltage, reliable low cost monolithically formed interconnections, design flexibility, costs that are independent of array voltage, and low power loss from shorts, opens, and impact damage. This concentrator solar cell will incorporate the benefits of light trapping by growing the device active layers over a low-cost, simple, PECVD deposited silicon/silicon dioxide Bragg reflector. The high voltage-low current output results in minimal 12R losses while properly designing the device allows for minimal shading and resistance losses. It is possible to obtain open circuit voltages as high as 67 volts/cm of solar cell length with existing technology. The projected power density for the high performance device is 5 kW/m for an AMO efficiency of 26% at 1 5X. Concentrator solar cell arrays are necessary to meet the power requirements of specific mission platforms and can supply high voltage power for electric propulsion systems. It is anticipated that the high efficiency, GaAs monolithically interconnected linear concentrator solar cell array will enjoy widespread application for space based solar power needs. Additional applications include remote man-portable or ultra-light unmanned air vehicle (UAV) power supplies where high power per area, high radiation hardness and a high bus voltage or low bus current are important. The monolithic approach has a number of inherent advantages, including reduced cost per interconnect and increased reliability of array connections. There is also a high potential for a large number of consumer products. Dual-use applications can include battery chargers and remote power supplies for consumer electronics products such as portable telephones/beepers, portable radios, CD players, dashboard radar detectors, remote walkway lighting, etc.

Dinetta, L. C.↗

NASA NTRS1995

A scientific assessment of a new technology orbital telescope

As part of a program designed to test the Alpha chemical laser weapons system in space, the Ballistic Missile Defense Organization (BMDO) developed components of an agile, lightweight, 4-meter telescope, equipped with an advanced active-optics system. BMDO had proposed to make space available in the telescope's focal plane for instrumentation optimized for scientific applications in astrophysics and planetary astronomy for a potential flight mission. Such a flight mission could be undertaken if new or additional sponsorship can be found. Despite this uncertainty, BMDO requested assistance in defining the instrumentation and other design aspects necessary to enhance the scientific value of a pointing and tracking mission. In response to this request, the Space Studies Board established the Task Group on BMDO New Technology Orbital Observatory (TGBNTOO) and charged it to: (1) provide instrumentation, data management, and science-operations advice to BMDO to optimize the scientific value of a 4-meter mission; and (2) support a space studies board assessment of the relative scientific merit of the program. This report deals with the first of these tasks, assisting the Advanced Technology Demonstrator's (ATD's) program scientific potential. Given the potential scientific aspects of the 4-meter telescope, this project is referred to as the New Technology Orbital Telescope (NTOT), or as the ATD/NTOT, to emphasize its dual-use character. The task group's basic conclusion is that the ATD/NTOT mission does have the potential for contributing in a major way to astronomical goals.

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NASA NTRS1996

Coordinated Fuel Cell System Programs for Government and Commercial Applications: Are We in a New Era?

Though the fuel cell was invented in 1839, it was not until the early 1960's that the fuel cell power system was developed and used for a real application, for the NASA Space Mission Gemini. Unfortunately, fuel cell power systems did not, as a result, become in widespread use. Nevertheless, a great deal of progress has been made by both government and industry, culminating in many successful fuel cell power system demonstrations. Initially, each government agency and each private organization went its own way. Later, it became evident that coordination among programs was essential. An overview is presented of the current coordinated efforts by government and industry in fuel cells, with a sufficient historical background. The primary barriers to coordination of programs were institutional and differing application requirements. Initially, in the institutional area, it was the energy crisis and the formation of DOE which fostered close working relationships among government, manufacturers, and users. The authors discuss the fuel cell power system programs (of NASA, DOE, DOT, DOC, EPRI, GRI, industry, and universities), including missions and applications, technology advances, and demonstrations. The discussion covers the new Solar Regenerative Fuel Cell (RFC) program which has space, defense, and commercial terrestrial applications, and which is an excellent example of both program coordination and the Clinton Administration's dual-use application policy.

Warshay, Marvin↗

NASA NTRS1996

Space Power Requirements for Future NASA Missions

The key technology issues for the power requirements of future NASA space missions are: reduction in mass to enable smaller launch vehicles, faster trip time and lower cost; simpler more autonomous operations to reduce life cycle cost; reduce design, development , and qualification time to enable frequent low-cost missions; increase payload fraction and science return; enable next generation missions; stimulate U.S. industry to promote strong world leadership capability; and incorporate dual-use strategy into technology development.

Mulville, Daniel R.↗

NASA NTRS1994

Modal Test Technology as Non-Destructive Evaluation of Space Shuttle Structures

Modal test and analysis Is being used for nondestructive evaluation of Space Shuttle structures. The purpose of modal testing is to measure the dynamic characteristics of a structure to extract its resonance frequencies, damping, and mode shapes. These characteristics are later compared to subsequently acquired characteristics. Changes in the modal characteristics indicate damage in the structure. Use of modal test technology as a damage detection tool was developed at JSC during the Shuttle acoustic certification program and subsequent test programs. The Shuttle Modal Inspection System was created in order to inspect areas that are impossible or impractical to inspect with conventional methods. Areas on which this technique has been applied include control surfaces, which are covered with thermal protection tiles, and the Forward Reaction Control Module, which is a frame structure that supports various tanks, thrusters, and fluid lines, which requires major disassembly to inspect. This paper traces the development of the technology, gives a status of its implementation on the Shuttle, explains challenges involved in implementing this type of inspection program, and suggests future improvements in data analysis and interpretation. Dual-use applications of the technology include inspections of bridges, oil-platforms, and aircraft.

Micheal S Grygler↗

NASA NTRS1994

Development of Advanced Alloys using Fullerenes

Development of advanced alloys using fullerenes is currently underway to produce materials for use in the extravehicular mobility unit (EMU). These materials will be directed toward commercial usages as they are continually developed. Fullerenes (of which the most common is C(sub 60)) are lightweight, nanometer size, hollow molecules of carbon which can be dispersed in conventional alloy systems to enhance strength and reduce weight. In this research, fullerene interaction with aluminum is investigated and a fullerene-reinforced aluminum alloy is being developed for possible use on the EMU. The samples were manufactured using standard commercial approaches including powder metallurgy and casting. Alloys have been processed having 1.3, 4.0 and 8.0 volume fractions of fullerenes. It has been observed that fullerene dispersion is related to the processing approach and that they are stable for the processing conditions used in this research. Emphasis will be given to differential thermal analysis and wavelength dispersive analysis of the processed alloys. These two techniques are particularly useful in determining the condition of the fullerenes during and after processing. Some discussion will be given as to electrical properties of fullerene-reinforced materials. Although the aluminum and other advanced alloys with fullerenes are being developed for NASA and the EMU, the properties of these materials will be of interest for commercial applications where specific Dual-Use will be given.

Sims, J.↗

NASA NTRS1996

The TMI Regenerative Solid Oxide Fuel Cell

Energy storage and production in space requires rugged, reliable hardware which minimizes weight, volume, and maintenance while maximizing power output and usable energy storage. Systems generally consist of photovoltaic solar arrays which operate (during sunlight cycles) to provide system power and regenerate fuel (hydrogen) via water electrolysis and (during dark cycles) fuel cells convert hydrogen into electricity. Common configurations use two separate systems (fuel cell and electrolyzer) in conjunction with photovoltaic cells. Reliability, power to weight and power to volume ratios could be greatly improved if both power production (fuel cells) and power storage (electrolysis) functions can be integrated into a single unit. The solid oxide fuel cell (SOFC) based design integrates fuel cell and electrolyzer functions and potentially simplifies system requirements. The integrated fuel cell/electrolyzer design also utilizes innovative gas storage concepts and operates like a rechargeable 'hydrogen-oxygen battery'. Preliminary research has been completed on improved H2/H20 electrode (SOFC anode/electrolyzer cathode) materials for regenerative fuel cells. Tests have shown improved cell performance in both fuel and electrolysis modes in reversible fuel cell tests. Regenerative fuel cell efficiencies, ratio of power out (fuel cell mode) to power in (electrolyzer mode), improved from 50 percent using conventional electrode materials to over 80 percent. The new materials will allow a single SOFC system to operate as both the electolyzer and fuel cell. Preliminary system designs have also been developed to show the technical feasibility of using the design for space applications requiring high energy storage efficiencies and high specific energy. Small space systems also have potential for dual-use, terrestrial applications.

Cable, Thomas L.↗

NASA NTRS1997

Chemical Gas Sensors for Aeronautic and Space Applications

Aeronautic and space applications require the development of chemical sensors with capabilities beyond those of commercially available sensors. Two areas of particular interest are safety monitoring and emission monitoring. In safety monitoring, detection of low concentrations of hydrogen at potentially low temperatures is important while for emission monitoring the detection of nitrogen oxides, hydrogen, hydrocarbons and oxygen is of interest. This paper discusses the needs of aeronautic and space applications and the point-contact sensor technology being developed to address these needs. The development of these sensors is based on progress in two types of technology: (1) Micromachining and microfabrication technology to fabricate miniaturized sensors. (2) The development of high temperature semiconductors, especially silicon carbide. The detection of each type of gas involves its own challenges in the fields of materials science and fabrication technology. The number of dual-use commercial applications of this microfabricated gas sensor technology make this general area of sensor development a field of significant interest.

Hunter, Gary W.↗

NASA NTRS1997

PMMW Camera TRP

Passive millimeter wave (PMMW) sensors have the ability to see through fog, clouds, dust and sandstorms and thus have the potential to support all-weather operations, both military and commercial. Many of the applications, such as military transport or commercial aircraft landing, are technologically stressing in that they require imaging of a scene with a large field of view in real time and with high spatial resolution. The development of a low cost PMMW focal plane array camera is essential to obtain real-time video images to fulfill the above needs. The overall objective of this multi-year project (Phase 1) was to develop and demonstrate the capabilities of a W-band PMMW camera with a microwave/millimeter wave monolithic integrated circuit (MMIC) focal plane array (FPA) that can be manufactured at low cost for both military and commercial applications. This overall objective was met in July 1997 when the first video images from the camera were generated of an outdoor scene. In addition, our consortium partner McDonnell Douglas was to develop a real-time passive millimeter wave flight simulator to permit pilot evaluation of a PMMW-equipped aircraft in a landing scenario. A working version of this simulator was completed. This work was carried out under the DARPA-funded PMMW Camera Technology Reinvestment Project (TRP), also known as the PMMW Camera DARPA Joint Dual-Use Project. In this final report for the Phase 1 activities, a year by year description of what the specific objectives were, the approaches taken, and the progress made is presented, followed by a description of the validation and imaging test results obtained in 1997.

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NASA NTRS1998

Space Station Cathode Design, Performance, and Operating Specifications

A plasma contactor system was baselined for the International Space Station (ISS) to eliminate/mitigate damaging interactions with the space environment. The system represents a dual-use technology which is a direct outgrowth of the NASA electric propulsion program and, in particular, the technology development efforts on ion thruster systems. The plasma contactor includes a hollow cathode assembly (HCA), a power electronics unit, and a xenon gas feed system. Under a pre-flight development program, these subsystems were taken to the level of maturity appropriate for transfer to U.S. industry for final development. NASA's Lewis Research Center was subsequently requested by ISS to manufacture and deliver the engineering model, qualification model, and flight HCA units. To date, multiple units have been built. One cathode has demonstrated approximately 28,000 hours lifetime, two development unit HCAs have demonstrated over 10,000 hours lifetime, and one development unit HCA has demonstrated more than 32,000 ignitions. All 8 flight HCAs have been manufactured, acceptance tested, and are ready for delivery to the flight contractor. This paper discusses the requirements, mechanical design, performance, operating specifications, and schedule for the plasma contactor flight HCAs.

Patterson, Michael J.↗

NASA NTRS1998

Chemical Gas Sensors for Aeronautic and Space Applications 2

Aeronautic and Space applications require the development of chemical sensors with capabilities beyond those of commercially available sensors. Areas of most interest include launch vehicle safety monitoring emission monitoring and fire detection. This paper discusses the needs of aeronautic and space applications and the point-contact sensor technology being developed to address these needs. The development of these sensor is based on progress two types of technology: 1) Micro-machining and micro-fabrication technology to fabricate miniaturized sensors. 2) The development of high temperature semiconductors, especially silicon carbide. Sensor development for each application involves its own challenges in the fields of materials science and fabrication technology. The number of dual-use commercial applications of this micro-fabricated gas sensor technology make this area of sensor development a field of significant interest.

Hunter, G. W.↗

NASA NTRS1998

Chemical Gas Sensors for Aeronautic and Space Applications 2

Aeronautic and space applications require the development of chemical sensors with capabilities beyond those of commercially available sensors. Areas of interest include launch vehicle safety monitoring, emission monitoring, and fire detection. This paper discusses the needs of aeronautic and space applications and the point-contact sensor technology being developed to address these needs. The development of these sensors is based on progress in two types of technology: 1) Micromachining and microfabrication technology to fabricate miniaturized sensors. 2) The development of high temperature semiconductors, especially silicon carbide. Sensor development for each application involves its own challenges in the fields of materials science and fabrication technology. The number of dual-use commercial applications of this microfabricated gas sensor technology make this area of sensor development a field of significant interest.

Hunter, Gary W.↗

NASA NTRS1997

Universal Signal Conditioning Amplifier

The Technological Research and Development Authority (TRDA) and NASA-KSC entered into a cooperative agreement in March of 1994 to achieve the utilization and commercialization of a technology development for benefiting both the Space Program and U.S. industry on a "dual-use basis". The technology involved in this transfer is a new, unique Universal Conditioning Amplifier (USCA) used in connection with various types of transducers. The project was initiated in partnership with I-Net Corporation, Lockheed Martin Telemetry & Instrumentation (formerly Loral Test and Information Systems) and Brevard Community College. The project consists of designing, miniaturizing, manufacturing, and testing an existing prototype of USCA that was developed for NASA-KSC by the I-Net Corporation. The USCA is a rugged and field-installable self (or remotely)- programmable amplifier that works in combination with a tag random access memory (RAM) attached to various types of transducers. This summary report comprises performance evaluations, TRDA partnership tasks, a project summary, project milestones and results.

Kinney, Frank↗

NASA NTRS1999

Chemical Gas Sensors for Aeronautics and Space Applications III

Hunter, G. W.↗

NASA NTRS2001

A Survey of Power Electronics Applications in Aerospace Technologies

The insertion of power electronics in aerospace technologies is becoming widespread. The application of semiconductor devices and electronic converters, as summarized in this paper, includes the International Space Station, satellite power system, and motor drives in 'more electric' technology applied to aircraft, starter/generators and reusable launch vehicles. Flywheels, servo systems embodying electromechanical actuation, and spacecraft on-board electric propulsion are discussed. Continued inroad by power electronics depends on resolving incompatibility of using variable frequency for 400 Hz-operated aircraft equipment. Dual-use electronic modules should reduce system development cost.

Kankam, M. David↗

NASA NTRS1997

Space Biosensor Systems: Implications for Technology Transfer

To meet the need for continuous, automated monitoring of animal subjects, including; humans, during space flight, NASA is developing advanced physiologic sensor and biotelemetry system technologies. The ability to continuously track basic physiological parameters, such as heart rate, blood pH, and body temperature, in untethered subjects in space is a challenging task. At NASA's Ames Research Center, where a key focus is gravitational biology research, engineers have teamed with life scientists to develop wireless sensor systems for automated physiologic monitoring of animal models as small as the rat. This technology is also being adapted, in collaboration with medical professionals, to meet human clinical monitoring needs both in space and on the ground. Thus, these advanced monitoring technologies have important dual-use functions; they meet space flight data collection requirements and constraints, while concurrently addressing a number of monitoring and data acquisition challenges on the ground in areas of clinical monitoring and biomedical research. Additional applications for these and related technologies are being sought and additional partnerships established that enhance development efforts, reduce costs and facilitate technology infusion between the public and private sectors. This paper describes technology transfer and co-development projects that have evolved out of NASA's miniaturized, implantable chemical sensor development efforts.

Hines, J. W.↗