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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Structure-activity relationship of Pt catalyst on engineered ceria-alumina support for CO oxidation

In heterogeneous catalysis, the promotion of low temperature activity and enhancement of thermal stability simultaneously especially for precious metal catalysts is always highly demanded but very challenging. In this work, we report a novel Pt catalyst on ceria-alumina (CeO 2 /Al 2 O 3 ) support (Pt/CA-T) engineered by a two-step ceria deposition strategy, exhibiting superior thermal stability and low-temperature carbon monoxide (CO) oxidation activity after activation. Pt single sites anchored to engineered CeO 2 edge sites are much more stable than that to CeO 2 (111) surface, and such stable single sites can be transformed into highly active Pt clusters for efficient low-temperature CO oxidation. Active site identification indicates that the CO oxidation activity of different Pt sites follows such sequence: Pt cluster step sites ≈ Pt cluster terrace sites > Pt cluster corner sites $\gg$ Pt single sites on CeO 2 . The excellent low temperature activity of activated Pt/CA-T catalyst for CO oxidation is associated with its abundant Pt cluster step and terrace sites as well as rich Pt-CeO 2 interfaces, which facilitate the adsorption of active CO species and superior oxygen activation/transfer ability. The present study provides new insights into the structure–activity relationship of Pt-CeO 2 -Al 2 O 3 catalyst, which can also guide the preparation of other highly robust supported catalysts for important industrial applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

U.S. Building Stock Characterization Study: A National Typology for Decarbonizing U.S. Buildings

To support the U.S. Department of Energy's (DOE's) Advanced Building Construction (ABC) Collaborative, the National Renewable Energy Laboratory (NREL) has been tasked with characterizing the U.S. building stock and developing a national typology of buildings. The potential use cases of such a typology are flexible and evolving, but in this initial phase, the primary intention is to help identify technology requirements and engineering solutions for moving the U.S. building stock toward a zero-carbon future by mid-century. This typology will also support the development of appropriate ABC research goals for existing buildings, such as cost targets for new technology development, and in a later phase, the typology can be used to support the implementation of ABC solutions by informing market aggregation and business model development. The ABC Initiative invests in new technologies that enable high building performance, can be deployed quickly with minimal onsite construction time, and are affordable and appealing to building owners, investors, and occupants. Funding awardees use many innovations, including new building materials, 3D printing, offsite manufacturing, robotics, and digital art-to-part. Although the goals of ABC cover a broad range of objectives around energy, comfort, and health, the primary ABC-related application of this national building characterization study is the development of retrofit packages that can be applied to reduce thermal loads in buildings. Retrofit packages will be determined collaboratively by the DOE and the ABC Collaborative. We anticipate a range of upgrade measures covering envelope-, HVAC-, and water-heating-related loads.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Utilizing data-based modeling with low life cycle GHG emissions algae biofuels for engine optimization

Aquatic microalgae are a highly promising feedstock for the production of biocrude and tailored biofuels, with distinct advantages over traditional terrestrial crops, such as reduced land use and avoidance of food production competition. However, unlocking their full potential requires the development of biofuels with low life cycle greenhouse emissions biofuels, such as algae biofuels, which can significantly reduce the environmental impact of the transportation systems without requiring a complete overhaul of existing engine technology. In this study, we employ cutting-edge data-based AI modeling techniques to optimize the performance of heavy-duty engines, with a focus on transitioning towards biofuels with low life cycle greenhouse emissions biofuels. Our methodology offers significant advantages over traditional sweep testing, enabling efficient and accurate optimization of engine performance with minimal time and resources consumption. Our findings demonstrate the potential of utilizing this approach, with up to 55% NOx emissions reductions and up to 2% reduction in fuel consumption compared to the baseline optimized point. Moving forward, we plan to utilize a 30% blend of algae biofuels with diesel fuel, with the ultimate goal of achieving up to 60% lifecycle GHG emissions. Lastly, we plan to compare the results with 100% renewable biodiesel to add an additional dimension of investigating the impact of fuel chemistry on engine optimization. Overall, this study underscores the vital importance of biofuels for reducing the carbon footprint of the transportation sector and supporting a sustainable future. By harnessing the power of data-based AI modeling with low life cycle greenhouse emissions biofuels, we can accelerate the adoption of more environmentally friendly transportation systems and reduce their impact on the planet. Our findings contribute to this transition and offer insights for developing efficient and effective strategies for addressing global climate change.

09 BIOMASS FUELS↗
DOE OSTI2024

Towards Marine Carbon Dioxide Removal (mCDR) Centers of Excellence

A diverse portfolio of carbon dioxide removal (CDR) technologies will be essential to meeting climate goals while supporting sustainable development. In particular, marine carbon dioxide removal (mCDR) methods can help diversify the existing portfolio, which currently relies heavily on engineered direct air capture systems for large-scale atmospheric removals. To fulfill their potential in the CDR ecosystem, these early-stage mCDR technologies require additional research and development. Here, we propose regional mCDR Technology Centers of Excellence that will provide inventors and developers with access to right-scale facilities and engineering expertise that will meet their needs wherever they are on the journey from bench- to pilot-scale development. To support innovation across the technological readiness level spectrum, these Centers will provide collaborative access to ocean-based mCDR testing sites; other opportunities for partnering with multidisciplinary experts in technology development and commercialization; provide meaningful pathways for integrated engagement with local industrial and regulatory systems; and help in developing tailored, impactful community benefit models. Ideal sites are co-located in areas with a favorable natural environment for testing mCDR, well studied baselines, accessible infrastructure for multidisciplinary marine research, and technology commercialization support. As a case study, we offer the Pacific Northwest as particularly suitable for a regional mCDR Technology Center of Excellence given existing and potential growth of all the characteristics of ideal sites listed above, and which could especially benefit from the region’s growing marine climate technology sector. Last, we offer a brief whole-of-government perspective for supporting and regulating these Centers of Excellence, including identification of mCDR Science Centers of Excellence to ensure that the development of mCDR technologies dovetails with much-needed advancements in oceanographic observation and simulation infrastructure.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2012

Design and Assembly of an Integrated Metabolic Heat Regenerated Temperature Swing Adsorption (MTSA) Subassembly Engineering Development Unit

Metabolic heat regenerated Temperature Swing Adsorption (MTSA) technology is being developed for thermal and carbon dioxide (CO2) control for a Portable Life Support System (PLSS), as well as water recycling. The core of the MTSA technology is a sorbent bed that removes CO2 from the PLSS ventilation loop gas via a temperature swing. A Condensing Icing Heat eXchanger (CIHX) is used to warm the sorbent while also removing water from the ventilation loop gas. A Sublimation Heat eXchanger (SHX) is used to cool the sorbent. Research was performed to explore an MTSA designed for both lunar and Martian operations. Previously the sorbent bed, CIHX, and SHX had been built and tested individually on a scale relevant to PLSS operations, but they had not been done so as an integrated subassembly. Design and analysis of an integrated subassembly was performed based on this prior experience and an updated transient system model. Focus was on optimizing the design for Martian operations, but the design can also be used in lunar operations. An Engineering Development Unit (EDU) of an integrated MTSA subassembly was assembled based on the design. Its fabrication is discussed. Some details on the differences between the as-assembled EDU and the future flight unit are considered.

Padilla, Sebastian A.↗
NASA NTRS2011

Design and Assembly of an Integrated Metabolic Heat Regenerated Temperature Swing Adsorption (MTSA) Subassembly Engineering Development Unit

Metabolic heat regenerated Temperature Swing Adsorption (MTSA) technology is being developed for thermal and carbon dioxide (CO2) control for a Portable Life Support System (PLSS), as well as water recycling. The core of the MTSA technology is a sorbent bed that removes CO2 from the PLSS ventilation loop gas via a temperature swing. A Condensing Ice Heat eXchanger (CIHX) is used to warm the sorbent while also removing water from the ventilation loop gas. A Sublimation Heat eXchanger (SHX) is used to cool the sorbent. Research was performed to explore an MTSA designed for both lunar and Martian operations. Previously each the sorbent bed, CIHX, and SHX had been built and tested individually on a scale relevant to PLSS operations, but they had not been done so as an integrated subassembly. Design and analysis of an integrated subassembly was performed based on this prior experience and an updated transient system model. Focus was on optimizing the design for Martian operations, but the design can also be used in lunar operations. An Engineering Development Unit (EDU) of an integrated MTSA subassembly was assembled based on the design. Its fabrication is discussed. Some details on the differences between the as-assembled EDU to the future flight unit are considered.

Padilla, Sebastian A.↗
NASA NTRS2003

Sabatier Engineering Development Unit

To facilitate life support system loop closure on board the International Space Station (ISS), the Node 3 Oxygen Generation System (OGS) rack contains a functional scar to accommodate a carbon dioxide reduction assembly (CRA). As part of the effort to better understand and define the functional scar, significant risk mitigation activities have been performed. To address integration risks, a CRA Engineering Development Unit (EDU) has been developed that is functionally equivalent to a flight CRA and is suitable for integrating with ground based carbon dioxide removal and oxygen generation systems. The CRA EDU has been designed to be functionally equivalent to the Sabatier Reactor Subsystem (SRS) portion of the CRA. The design of the CRA EDU and testing results in a stand alone configuration with simulated OGA and CDRA interfaces are reported. Carbon dioxide flow control is a major area requiring development since the size of the CO2 accumulator may result in periods of CRA starvation. The capability of the CO2 flow control algorithm to effectively manage integrated CRA operations is discussed.

Perry, Jay↗
NASA NTRS2021

Hybrid Electric Aircraft Thermal Management: Now, New Visions and Future Concepts and Formulation

The global fuel consumption by commercial airlines has increased each year since 2009 and is predicted to reach an all-time high of 97 billion gallons in 2019. There is also an environmental impact from this: CO2 emissions from commercial passenger and freight operations totaled 918 Mt in 2018 (ICCT, 2019), or around 2.5% of global energy-related CO2 emissions. Passenger transport accounted for 81% of the total. Emissions from aviation have grown 32% over the past five years. Coupled with this aspect, there is a continuous and growing need to satisfy ever-growing electrical power needs on commercial and military aircraft. All the armed services (Army, Navy, and Air Force) are continuously trying to enhance UAV (unmanned aerial vehicle) endurance and range across a broad fleet of different aircraft. The commercial Boeing 787 requires about 1.2MWe and that is expected to grow. Current technologies used to supply increased on-board electrical power are generally: 1) “burn more fuel and convert through on-board generators” and 2) use additional heavy (i.e., weight-inefficient) and sometimes unsafe battery systems on-board the aircraft. The aircraft industry is seeking new, innovative ways to satisfy this increasing power demand. One as-yet-untapped power source is the enormous amount of “waste” thermal energy flowing out the jet engine exhaust; some estimates in smaller “by-pass” flow jet engines is several hundreds of kilowatts (e.g., Pratt & Whitney Canada PW545B turbofan). This quantity is much higher in large jet engines associated with commercial aircraft. This large waste thermal energy manifests itself in large temperature differences within the by-pass-flow engine exhaust system relative to outside ambient conditions, because of the actual by-pass engine design configuration. There is strong need to develop thermal technologies and systems that could harness and convert at least a portion of this thermal energy into useful electrical energy to satisfy growing on-board electrical needs. In addition, there is a strong desire within the aircraft and engine manufacturing community to reduce the “carbon footprint” of the industry though reduced fuel usage worldwide. NASA has a robust aircraft electrification program to meet these desires and support industry in its aircraft electrification objectives. This program is integrating thermoacoustic systems, advanced lightweight heat exchanger technology, and advanced heat pipe technology to capture and transport large amounts of engine waste thermal energy for on-board power conversion, advanced heat-pump cooling, and exergy enhancement (i.e., temperature lift). Advanced lightweight heat exchangers are envisioned to capture engine exhaust thermal energy at approximately 673 K and deliver it to efficient thermoacoustic power conversion systems operating at temperature ratios (Thot/Tcold) > 1.6. Advanced heat pipe systems are envisioned to transport thermal energy from low temperature sources, through thermoacoustic heat pumps, to high temperature needs such as wing anti-icing, fuel pre-heating, and combustion air pre-heating. The paper will discuss the current state-of-the-art, objectives, system design architecture, and remaining technical challenges in system formulation within the NASA aircraft electrification program.

Dyson, Rodger↗
NASA NTRS1971

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

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

Source record↗
DOE OSTI2026

Adsorption-Engineered Hydrocarbon Ionomers for Durable Proton-Exchange Membrane Fuel Cells

Reducing reliance on perfluoroalkyl substances (PFAS) in proton-exchange membrane fuel cells requires hydrocarbon ionomers that combine high performance with long-term durability, a persistent challenge in catalyst-layer design. Here, we identify oxidation-driven ionomer-catalyst interfacial degradation as a dominant failure pathway in hydrocarbon ionomer-bonded cathodes and introduce an adsorption-engineering strategy to overcome this limitation. The comparison of a commercial sulfonated poly(phenylene) (Pemion) with structurally engineered sulfonated poly(fluorene)s demonstrated that electrode durability is governed by the interplay between ionomer adsorption strength and resistance to oxidative degradation on carbon-supported Pt catalysts. A poly(fluorene) ionomer with mobile alkyl sulfonic acid groups forms resilient interfaces, delivering 1.28 A cm−2 at 0.65 V under fully humidified H2/air conditions (80°C and 150 kPaabs), comparable to Pemion. After 90,000 accelerated potential cycles, the poly(fluorene)-bonded cathode exhibits significantly improved durability, with only 29% performance loss compared to 58% for Pemion; further molecular refinement reduces the loss to 17%, approaching that of Nafion-bonded cathodes (14%). These findings establish adsorption-engineered ionomer design that decouples interfacial anchoring from oxidative degradation as a general strategy for achieving durable, high-performance PFAS-free PEM fuel cell electrodes.

08 HYDROGEN↗
DOE OSTI2025

PCOR partnership initiative to accelerate CCCUS deployment

The Plains CO 2 Reduction (PCOR) Partnership Initiative, led by the Energy & Environmental Research Center (EERC), was a 5-year collaborative effort under the U.S. Department of Energy’s Regional Initiative to Accelerate CCUS (carbon capture, utilization, and storage). With support from the University of Wyoming School of Energy Resources (UW SER), the University of Alaska Fairbanks Institute of Northern Engineering (UAF INE), and a broad network of public and private stakeholders, the program focused on overcoming regional challenges to CCUS across ten U.S. states and four Canadian provinces. This report summarizes the notable findings of the EERC and its collaborators through the 5-year PCOR Partnership Initiative phase. The EERC developed and demonstrated a risk-based area of review (AOR) workflow for U.S. Environmental Protection Agency Class VI carbon dioxide (CO 2 ) storage permitting.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Action at a distance: The remarkable coupling of CO 2 uptake to electron transfer in specialized cyanobacterial NDH-1 complexes

Cyanobacteria achieve highly efficient photosynthesis using a CO 2 -concentrating mechanism relying on specialized Type I (NDH-1) complexes. Among these, NDH-1 3 and NDH-1 4 catalyze redox-coupled hydration of CO 2 to bicarbonate, supporting carbon fixation in carboxysomes. The mechanism of coupling electron transfer to CO 2 -hydration by these variant NDH-1 complexes remains unknown. We engineered a Synechococcus PCC7942 strain that expresses exclusively the high flux/low affinity NDH-14 complex, enabling the observation of the coupling of CO 2 hydration to cyclic electron flow in isolation from the other NDH-1 isoforms normally present in cells. We found that inhibition of the CupB protein by the carbonic anhydrase inhibitor ethoxzolamide (EZ) suppressed CO 2 uptake, slowed photosystem I rereduction, and abolished proton pumping as probed by acridine orange fluorescence. These effects were absent in strains lacking Cup proteins, confirming specificity. The results demonstrate that CO 2 hydration and electron transfer through NDH-14 are tightly coupled via proton translocation across the thylakoid membrane. These findings provide direct evidence for the bidirectional interaction in bioenergetic coupling between the plastoquinone reduction and the CO 2 uptake at the distal Zn-site over a span of ~150 Å and support a proton-removal hypothesis involving the proton transfer pathways from the Zn-site of CO2 hydration to an energetically coupled proton loading site evolutionarily repurposed from the ancestral proton pumping mechanism to enable energetic CO 2 uptake.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2010

Launch Pad Coatings for Smart Corrosion Control

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

Calle, Luz M.↗
DOE OSTI2021

FEED Study of Carbon Capture Inc. DAC and CarbonCure Utilization Using United States Steel's Gary Works Waste Plant

Direct Air Capture (DAC) has been proposed as a means of reducing atmospheric concentrations of CO2. While DAC has been evaluated through lab-scale, bench-scale, and small-scale pilot units, large-scale deployment has not been achieved. Feasibility studies are one tool to understand the potential design, operation, performance, and impact of commercial-scale DAC. This paper presents the results of a feasibility study for a passive DAC system deployed at >100,000 tpy scale in three different regions across the U.S. and awarded to Carbon Collect by the U.S. Department of Energy National Energy Technology Laboratory (DOE NETL). The MechanicalTree™technology has been designed and engineered by Carbon Collect based on the concept initially developed at Arizona State University Center for Negative Carbon Emissions. It uses a tower of stacked, sorbentcontaining disks supported by a lifting mechanism, exposed to the air to capture CO2 during the adsorption phase. The disks are then lowered into a regeneration chamber for vacuum and steam regeneration to produce CO2 product during the desorption step. The modular tree design allows large installations with repeatable, mass-manufactured units connected to common utilities such as steam supply, vacuum, and CO2 processing for compression and geologic storage. The passive DAC system eliminates the equipment and energy of forced air fans by using natural air circulation to contact the sorbent with the CO2 in the air. Because of this, the performance is dependent on the wind speed in addition to the temperature and relative humidity. Performance and flow rate fluctuations were incorporated into equipment and facility design with considerations for turndown to 10% of maximum rated flow to allow operation in all seasons. The feasibility study was undertaken to evaluate the technology in different regions and climates. Three locations were selected for this study representing different climates: Alabama (hot and humid), California (hot and arid), and Wyoming (continental). For each region, the adsorption/desorption cycle was optimized including tuning the heat integration and cycle timings. The performance of individual trees was then scaled to the full facility with the same design of more than 20,000 trees common between all regions. The installations had expected average CO2 capture rates of between 330,000 and 485,000 tonnes of CO2 per year depending on the climate. The initial engineering design for the facility at each location was performed with cost and performance estimates for the trees, carbon purification and compression, and the balance of plant. To supply thermal and electrical energy for the facility, carbon-free or low-carbon power must be considered. Options for low-carbon, continuous thermal and electrical energy were considered. The best-performing option from those considered was identified to be an electrically-heated molten salt energy storage system, powered by an on-site photovoltaic field. During molten salt thermal discharge, steam is produced from heat exchange with the molten salt and used to generate power in a steam turbine as well as steam for regenerating the DAC carbon trees. The thermal and electrical supply and analysis is presented in the context of low-carbon power for carbon removal. Modelling and economics of transportation and geologic storage of the CO2 is considered and presented for each location. The results of the feasibility study are incorporated into the presented techno-economic and life-cycle assessments. This work is intended to provide an understanding of the performance, cost, and impact of capturing CO2 at the commercial scale and the impact of climate and regional siting on the considered passive DAC system.

42 ENGINEERING↗
NASA NTRS1986

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

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

Suhoza, J. P.↗
NASA NTRS2015

Improving Interlaminar Shear Strength

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

Jackson, Justin↗
NASA NTRS2005

NSTAR Extended Life Test Discharge Chamber Flake Analysis

The Extended Life Test (ELT) of the NASA Solar Electric Propulsion Technology Readiness (NSTAR) ion thruster was concluded after 30,352 hours of operation. The ELT was conducted using the Deep Space 1 (DS1) back-up flight engine, a 30 cm diameter xenon ion thruster. Post-test inspection of the ELT engine revealed numerous contaminant flakes distributed over the bottom of the cylindrical section of the anode within the discharge chamber (DC). Extensive analyses were conducted to determine the source of the particles, which is critical to the understanding of degradation mechanisms of long life ion thruster operation. Analyses included: optical microscopy (OM) and particle length histograms, field emission scanning electron microscopy (FESEM) combined with energy dispersive spectroscopy (EDS), and atomic oxygen plasma exposure tests. Analyses of the particles indicate that the majority of the DC flakes consist of a layered structure, typically with either two or three layers. The flakes comprising two layers were typically found to have a molybdenum-rich (Mo-rich) layer on one side and a carbon-rich (C-rich) layer on the other side. The flakes comprising three layers were found to be sandwich-like structures with Mo-rich exterior layers and a C-rich interior layer. The presence of the C-rich layers indicates that these particles were produced by sputter deposition build-up on a surface external to the discharge chamber from ion sputter erosion of the graphite target in the test chamber. This contaminant layer became thick enough that particles spalled off, and then were electro-statically attracted into the ion thruster interior, where they were coated with Mo from internal sputter erosion of the screen grid and cathode components. Atomic oxygen tests provided evidence that the DC chamber flakes are composed of a significant fraction of carbon. Particle size histograms further indicated that the source of the particles was spalling of carbon flakes from downstream surfaces. Analyses of flakes taken from the downstream surface of the accelerator grid provided additional supportive information. The production of the downstream carbon flakes, and hence the potential problems associated with the flake particles in the ELT ion thruster engine is a facility induced effect and would not occur in the space environment.

deGroh, Kim K.↗
NASA NTRS1991

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

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

Zhao, Y.↗