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All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Evolving Design Criteria for Very Large Aperture Space Based Telescopes and Their Influence on the Need for Integrated Tools in the Optimization Process

NASA's Advanced Mirror Technology Development (AMTD) program has been developing the means to design and build the future generations of space based telescopes. With the nearing completion of the James Webb Space Telescope (JWST), the astrophysics community is already starting to define the requirements for follow-on observatories. The restrictions of available launch vehicles and the possibilities of planned future vehicles have fueled the competition between monolithic primaries (with better optical quality) and segmented primaries (with larger apertures, but with diffraction, costs and figure control issues). Regardless of the current shroud sizes and lift capacities, these competing architectures share the need for rapid design tools. As part of the AMTD program a number of tools have been developed and tested to speed up the design process. Starting with the Arnold Mirror Modeler (which creates Finite Element Models (FEM) for structural analysis) and now also feeds these models into thermal stability analyses. They share common file formats and interchangeable results. During the development of the program, numerous trade studies were created for 4-meter and 8-meter monolithic primaries, complete with support systems. Evaluation of these results has led to a better understanding of how the specification drives the results. This paper will show some of the early trade studies for typical specification requirements such as lowest mirror bending frequency and suspension system lowest frequency. The results use representative allowable stress values for each mirror substrate material and construction method and generic material properties. These studies lead to some interesting relationships between feasible designs and the realities of actually trying to build these mirrors. Much of the traditional specifications were developed for much smaller systems, where the mass and volume of the primary where a small portion of the overall satellite. JWST shows us that as the aperture grows, the primary takes up the majority of the mass and volume and the established rules need to be adjusted. For example, a small change in lowest frequency requirement can change the cost by millions of dollars. The paper uses numerous trade studies created during the software development phase of the Arnold Mirror Modeler to illustrate the influences of system specifications on the design space. The future telescopes will require better performance, stability and documented feasibility to meet the hurdles of today's budget and schedules realities. AMTD is developing the tools, but the basic system planning mentality also has to adopt to the requirements of these very large and complex physical structures.

Arnold, William R., Sr.↗
DOE OSTI2023

Modeling Advanced Strippers for CO2 Capture from Gas-Fired Power Plants using Aqueous Piperazine

Energy performance of 5 m piperazine was evaluated with an advanced stripper at the pilot scale, accounting for heat loss. Modeling studies indicated that heat loss at locations other than the heat source impacted the heat duty. For strippers with excess packing, the column was the most important source of heat loss, and values as low as 0.03 GJ/hr can cause pinch and reabsorption of CO2. Solvents like 5 m PZ are more affected by heat loss in the column due to a top-side temperature pinch at high lean loading. Heat loss impacts NGCC CO2 capture more than coal-based CO2 capture. Surface temperature measurements pilot plants showed that heat loss was 50-75% controlled by natural convection. Measured heat loss was correlated with steam flowrate and wind speed and ranged from 8126 to 219668 Btu/hr, representing 35% of the measured heat rate on average. Net heat duty linearly varied with CO2 removal at low lean loading and was similar for coal and NGCC conditions at fixed removal. At 90% removal, net heat duty was about 2.5 GJ/t with 4 and 12% CO2 in the flue gas. 7 At NGCC conditions, strippers with finite packing can benefit from a flashing feed to the top of the column by using a hot bypass. A flashing feed was linked to a reduction in irreversibility of the stripper from temperature driving forces. It also reduces heat duty by up to 6% at fixed packing height and reduces packing requirement for a fixed steam heater size compared to a warm bypass. Lean loading and lean solvent rate were effective handles to maximize profitability of a fixed stripper design at low gas price. High ambient temperature operation can benefit from low pressure stripping to about 0.18 lean loading at 150 ℃ to maintain the cyclic capacity at reduced rich loading. At low gas price, the capture plant was able to maximize profitability even with a high heat duty of 2.7-3.1 GJ/t at a lean loading of 0.2-0.22 mol/mol. Heat recovery by partial water vapor condensation in a gas-liquid exchanger can be replaced by a direct contact condenser (DCC). The DCC improved gas cooling and reduced heat duty compared to the CO2 exchanger at 0.2 lean loading. The DCC when used with a 150 ℃/5.5 bar stripper can reduce the cost of capture compared to the base case by $3- 4/tonne at 15 ft of packing (optimum) but increases cost of capture by $6/tonne with a 120 ℃/2 bar stripper and 10 ft of packing (optimum). The DCC can work effectively with a solvent with a high heat of absorption and thermal stability.

Suresh Babu, Athreya↗
NASA NTRS2015

Pathfinder Lander Rover Recharge System, and MARCO POLO Controls and ACME Regolith Feed System Controls and Integration

This project stems from the Exploration, Research, and Technology Directorate (UB) Projects Division, and one of their main initiatives is the "Journey to Mars". Landing on the surface of Mars which is millions of miles away is an incredibly large challenge. The terrain is covered in boulders, deep canyons, volcanic mountains, and spotted with sand dunes. The robotic lander is a kind of spacecraft with multiple purposes. One purpose is to be the protective shell for the Martian rover and absorb the impact from the landing forces; another purpose is to be a place where the rovers can come back to, actively communicate with, and recharge their batteries from. Rovers have been instrumental to the Journey to Mars initiative. They have been performing key research on the terrain of the red planet, trying to unlock the mysteries of the land for over a decade. The rovers that will need charging will not all have the same kind of internal battery either. RASSOR batteries may differ from the PbAC batteries inside Red Rover's chassis. NASA has invested heavily in the exploration of the surface of Mars. A driving force behind further exploration is the need for a more efficient operation of Martian rovers. One way is to reduce the weight as much as possible to reduce power consumption given the same mission parameters. In order to reduce the mass of the rovers, power generation, communication, and sample analysis systems currently onboard Martian rovers can be moved to a stationary lander deck. Positioning these systems from the rover to the Lander deck allows a taskforce of smaller, lighter rovers to perform the same tasks currently performed by or planned for larger rovers. A major task in transferring these systems to a stationary lander deck is ensuring that power can be transferred to the rovers.

Internship↗
NASA NTRS2006

2D/3D Visual Tracker for Rover Mast

A visual-tracker computer program controls an articulated mast on a Mars rover to keep a designated feature (a target) in view while the rover drives toward the target, avoiding obstacles. Several prior visual-tracker programs have been tested on rover platforms; most require very small and well-estimated motion between consecutive image frames a requirement that is not realistic for a rover on rough terrain. The present visual-tracker program is designed to handle large image motions that lead to significant changes in feature geometry and photometry between frames. When a point is selected in one of the images acquired from stereoscopic cameras on the mast, a stereo triangulation algorithm computes a three-dimensional (3D) location for the target. As the rover moves, its body-mounted cameras feed images to a visual-odometry algorithm, which tracks two-dimensional (2D) corner features and computes their old and new 3D locations. The algorithm rejects points, the 3D motions of which are inconsistent with a rigid-world constraint, and then computes the apparent change in the rover pose (i.e., translation and rotation). The mast pan and tilt angles needed to keep the target centered in the field-of-view of the cameras (thereby minimizing the area over which the 2D-tracking algorithm must operate) are computed from the estimated change in the rover pose, the 3D position of the target feature, and a model of kinematics of the mast. If the motion between the consecutive frames is still large (i.e., 3D tracking was unsuccessful), an adaptive view-based matching technique is applied to the new image. This technique uses correlation-based template matching, in which a feature template is scaled by the ratio between the depth in the original template and the depth of pixels in the new image. This is repeated over the entire search window and the best correlation results indicate the appropriate match. The program could be a core for building application programs for systems that require coordination of vision and robotic motion.

Bajracharya, Max↗
DOE OSTI2024

"Traffic Control via Connected and Automated Vehicles: An Open-Road Field Experiment with 100 CAVs"

The CIRCLES project aims to reduce instabilities in traffic flow, which are naturally occurring phenomena due to human driving behavior. These "phantom jams" or "stop-and-go waves,"are a significant source of wasted energy. Toward this goal, the CIRCLES project designed a control system referred to as the MegaController by the CIRCLES team, that could be deployed in real traffic. Our field experiment leveraged a heterogeneous fleet of 100 longitudinally-controlled vehicles as Lagrangian traffic actuators, each of which ran a controller with the architecture described in this paper. The MegaController is a hierarchical control architecture, which consists of two main layers. The upper layer is called Speed Planner, and is a centralized optimal control algorithm. It assigns speed targets to the vehicles, conveyed through the LTE cellular network. The lower layer is a control layer, running on each vehicle. It performs local actuation by overriding the stock adaptive cruise controller, using the stock on-board sensors. The Speed Planner ingests live data feeds provided by third parties, as well as data from our own control vehicles, and uses both to perform the speed assignment. The architecture of the speed planner allows for modular use of standard control techniques, such as optimal control, model predictive control, kernel methods and others, including Deep RL, model predictive control and explicit controllers. Depending on the vehicle architecture, all onboard sensing data can be accessed by the local controllers, or only some. Control inputs vary across different automakers, with inputs ranging from torque or acceleration requests for some cars, and electronic selection of ACC set points in others. The proposed architecture allows for the combination of all possible settings proposed above. Most configurations were tested throughout the ramp up to the MegaVandertest.

Lee, Jonathan↗
NASA NTRS2011

The J-2X Fuel Turbopump - Turbine Nozzle Low Cycle Fatigue Acceptance Rationale

The J-2X Fuel Turbopump (FTP) turbine, which drives the pump that feeds hydrogen to the J-2X engine for main combustion, is based on the J-2S design developed in the early 1970 s. Updated materials and manufacturing processes have been incorporated to meet current requirements. This paper addresses an analytical concern that the J-2X Fuel Turbine Nozzle Low Cycle Fatigue (LCF) analysis did not meet safety factor requirements per program structural assessment criteria. High strains in the nozzle airfoil during engine transients were predicted to be caused by thermally induced stresses between the vane hub, vane shroud, and airfoil. The heritage J-2 nozzle was of a similar design and experienced cracks in the same area where analysis predicted cracks in the J-2X design. Redesign options that did not significantly impact the overall turbine configuration were unsuccessful. An approach using component tests and displacement controlled fracture mechanics analysis to evaluate LCF crack initiation and growth rate was developed. The results of this testing and analysis were used to define the level of inspection on development engine test units. The programmatic impact of developing crack initiation/growth rate/arrest data was significant for the J-2X program. Final Design Certification Review acceptance logic will ultimately be developed utilizing this test and analytical data.

Hawkins, Lakiesha V.↗
DOE OSTI2025

Traffic Control via Connected and Automated Vehicles (CAVs): An Open-Road Field Experiment with 100 CAVs

The CIRCLES project aims to reduce instabilities in traffic flow, which are naturally occurring phenomena due to human driving behavior. Also called “phantom jams” or “stop-and-go waves,” these instabilities are a significant source of wasted energy. Toward this goal, the CIRCLES project designed a control system, referred to as the MegaController by the CIRCLES team, that could be deployed in real traffic. Our field experiment, the MegaVanderTest (MVT), leveraged a heterogeneous fleet of 100 longitudinally controlled vehicles as Lagrangian traffic actuators, each of which ran a controller with the architecture described in this article. The MegaController is a hierarchical control architecture that consists of two main layers. The upper layer is called the Speed Planner and is a centralized optimal control algorithm. It assigns speed targets to the vehicles, conveyed through the LTE cellular network. The lower layer is a control layer, running on each vehicle. It performs local actuation by overriding the stock adaptive cruise controller, using the stock onboard sensors. The Speed Planner ingests live data feeds provided by third parties as well as data from our own control vehicles and uses both to perform the speed assignment. The architecture of the Speed Planner allows for the modular use of standard control techniques, such as optimal control, model predictive control (MPC), kernel methods, and others. The architecture of the local controller allows for the flexible implementation of local controllers. Corresponding techniques include deep reinforcement learning (RL), MPC, and explicit controllers. Depending on the vehicle architecture, all onboard sensing data can be accessed by the local controllers or only some. Likewise, control inputs vary across different automakers, with inputs ranging from torque or acceleration requests for some cars to electronic selection of adaptive cruise control (ACC) setpoints in others. The proposed architecture technically allows for the combination of all possible settings proposed previously, that is {Speed Planner algorithms} × {local Vehicle Controller algorithms} × {full or partial sensing} × {torque or speed control}. As a result, most configurations were tested throughout the ramp up to the MegaVandertest (MVT).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Clostridium autoethanogenum alters cofactor synthesis, redox metabolism, and lysine-acetylation in response to elevated H 2 :CO feedstock ratios for enhancing carbon capture efficiency

Clostridium autoethanogenum is an acetogenic bacterium that autotrophically converts carbon monoxide (CO) and carbon dioxide (CO 2 ) gases into bioproducts and fuels via the Wood–Ljungdahl pathway (WLP). To facilitate overall carbon capture efficiency, the reaction stoichiometry requires supplementation of hydrogen at an increased ratio of H 2 :CO to maximize CO 2 utilization; however, the molecular details and thus the ability to understand the mechanism of this supplementation are largely unknown. In order to elucidate the microbial physiology and fermentation where at least 75% of the carbon in ethanol comes from CO 2 , we established controlled chemostats that facilitated a novel and high (11:1) H 2 :CO uptake ratio. We compared and contrasted proteomic and metabolomics profiles to replicate continuous stirred tank reactors (CSTRs) at the same growth rate from a lower (5:1) H 2 :CO condition where ~ 50% of the carbon in ethanol is derived from CO 2 . Our hypothesis was that major changes would be observed in the hydrogenases and/or redox-related proteins and the WLP to compensate for the elevated hydrogen feed gas. Our analyses did reveal protein abundance differences between the two conditions largely related to reduction–oxidation (redox) pathways and cofactor biosynthesis, but the changes were more minor than we would have expected. While the Wood–Ljungdahl pathway proteins remained consistent across the conditions, other post-translational regulatory processes, such as lysine-acetylation, were observed and appeared to be more important for fine-tuning this carbon metabolism pathway. Metabolomic analyses showed that the increase in H 2 :CO ratio drives the organism to higher carbon dioxide utilization resulting in lower carbon storages and accumulated fatty acid metabolite levels. This research delves into the intricate dynamics of carbon fixation in C. autoethanogenum, examining the influence of highly elevated H 2 :CO ratios on metabolic processes and product outcomes. The study underscores the significance of optimizing gas feed composition for enhanced industrial efficiency, shedding light on potential mechanisms, such as post-translational modifications (PTMs), to fine-tune enzymatic activities and improve desired product yields.

09 BIOMASS FUELS↗
DOE OSTI2024

Design of the cryogenic moderator system for the second target station

The Second Target Station (STS) at Oak Ridge National Laboratory will be a 700 kW pulsed spallation neutron source designed to provide the world's highest brightness cold neutron beams. In order to produce the required neutron performance, two compact liquid hydrogen moderators are located adjacent to the tungsten spallation target and must be supplied with less than 20 K hydrogen and a para hydrogen fraction of 99.8% or greater. The Cryogenic Moderator System (CMS) will consist of a single hydrogen loop feeding the two moderators in series cooled by a helium refrigerator with a cooling capacity of 2.5 kW at 17 K. The hydrogen loop consists of a hydrogen circulator, hydrogen helium heat exchanger, ortho-para converter, accumulator, transfer lines and heater. The design of the hydrogen loop is based on the CMS design of the First Target Station at the Spallation Neutron Source and some of the component designs may be reused. General hydrogen temperature control is provided by controlling the flowrate of helium to the heat exchanger. The hydrogen loop will have a constant flowrate of 0.5 L/s and remove a nuclear heat load of about 850 W from the two moderators, which is deposited both directly in the hydrogen and the adjacent hydrogen containing structures. Because the nuclear heat load is accelerator driven, the hydrogen system must remain stable when the heat load is removed instantaneously during beam trips. System stability is maintained passively with the accumulator and actively with the heater. Ionizing radiation which interacts with the liquid hydrogen drives backconversion of the hydrogen from parahydrogen to orthohydrogen. The STS moderator performance is very sensitive to small fractions of orthohydrogen requiring an ortho-para converter to maintain the hydrogen supplied to the moderators at near equilibrium parahydrogen concentration. STS CMS is in the early stage of preliminary design and current focus is evaluating component sizing and system stability during beam transients.

Janney, Jim↗
DOE OSTI2026

Beyond Thermal Limits: Manipulating Reactive Intermediate Coverages and Turnover Rates via Visible Photon-Mediated Catalysis on Rh-Doped Perovskite Oxides

Catalyst behavior depends on surface adsorbate energetics that are constrained by scaling relationships on metal surfaces. External stimuli (e.g., photons), however, can disrupt these limitations by modulating key intermediate coverages via non-thermal reaction pathways. Here, low-energy visible photon fluxes are utilized to selectively control coverages of strongly bound intermediates on isolated Rh active sites doped within a semiconductor perovskite oxide host (SrTiO 3 ). Red light (632 nm) facilitates selective photolytic CO desorption from rhodium gem-dicarbonyl (Rh(CO) 2 ) species that are ubiquitous reaction intermediates, including for the probe reaction studied herein CO oxidation to CO 2 . Thermochemical CO 2 formation rates (408 K) on Rh-doped SrTiO 3 are limited by adsorbed CO, exhibiting a negative apparent CO rate order (−0.6) and a positive O 2 rate order (+0.4). Arrhenius analyses, anaerobic CO oxidation measurements, and in situ spectroscopies assert that, thermochemically, lattice oxygens from the doped perovskite contribute to CO 2 formation rates. Notably, under red light illumination (0.76–2.02 W cm –2 ), the apparent CO rate order shifts to positive (+1). This, combined with decreasing apparent activation energies and CO coverages (wavelength-agnostic) with increasing photon flux, indicates that photons act selectively toward driving Rh(CO) 2 photolysis, even within complex reaction networks, thereby enhancing Rh accessibility, O 2 dissociation, and consequent rates. Finally, low-energy red light enables more stoichiometric feeds, leading to 650% higher CO 2 rates than those achieved thermally. Overall, this work elucidates how low-energy light can be leveraged, not just to improve reaction rates, but to selectively affect rates of individual elementary steps and key intermediate coverages, thereby breaking conventional scaling relationships that limit thermal catalyst performance.

catalysts↗
DOE OSTI2023

Conceptual design of the LHCD system on CFETR

With the capability of saving flux consumption in the current ramp up phase, controlling the safety factor (q) profile, providing the required off-axis current drive (CD), a lower hybrid current drive (LHCD) system was eventually determined to be used on the China Fusion Engineering Test Reactor (CFETR). Here, in this paper, a 20 MW/4.6 GHz system composed of 40 units of 500 kW continuous wave (CW) klystron amplifier is preliminarily designed. The feasibility of the frequency choice of 4.6 GHz in the physical aspect is discussed. In order to minimize the transmission loss, a TE01 over-mode of circular waveguide will be used in the transmission system. Although previous calculations indicates that high field side (HFS) launcher location results in waves damping at inner region than low field side (LFS) launcher, which is favorable for plasma stability, HFS launcher will be extremely difficult in engineering due to the limited space. Calculations show that the tritium breeding ratio (TBR) will be decreased by ~ 1.5% with HFS launcher, while it will be decreased by ~ 0.22% only with LFS launcher. As a result, the LH power will be coupled to plasma from the top port at LFS. The designed passive active multi-junction (PAM) launcher is arranged in an array of 5 rows and 8 columns with the height of 1181 mm and the width of 794 mm. A shielding block with a thickness of 20 cm will be equipped around the feeding waveguides to protect the feeding waveguides and to prevent neutron leakage. A preliminary scheme of the remote maintenance for the LFS launcher is given. The modeling results shows that the density for optimum coupling is ~ 1.8 × 10 17 /m 3 , lower than the 4.6 GHz cut-off density n e_co = 2.6 × 10 17 /m 3 . Around this density, the power directivity (D p ) can be high as 71%.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2016

The Sustainability of Habitability on Terrestrial Planets: Insights, Questions, and Needed Measurements from Mars for Understanding the Evolution of Earth-Like Worlds

What allows a planet to be both within a potentially habitable zone and sustain habitability over long geologic time? With the advent of exoplanetary astronomy and the ongoing discovery of terrestrial-type planets around other stars, our own solar system becomes a key testing ground for ideas about what factors control planetary evolution. Mars provides the solar systems longest record of the interplay of the physical and chemical processes relevant to habitability on an accessible rocky planet with an atmosphere and hydrosphere. Here we review current understanding and update the timeline of key processes in early Mars history. We then draw on knowledge of exoplanets and the other solar system terrestrial planets to identify six broad questions of high importance to the development and sustaining of habitability (unprioritized): (1) Is small planetary size fatal? (2) How do magnetic fields influence atmospheric evolution? (3) To what extent does starting composition dictate subsequent evolution, including redox processes and the availability of water and organics? (4) Does early impact bombardment have a net deleterious or beneficial influence? (5) How do planetary climates respond to stellar evolution, e.g., sustaining early liquid water in spite of a faint young Sun? (6) How important are the timescales of climate forcing and their dynamical drivers? Finally, we suggest crucial types of Mars measurements (unprioritized) to address these questions: (1) in situ petrology at multiple units/sites; (2) continued quantification of volatile reservoirs and new isotopic measurements of H, C, N, O, S, Cl, and noble gases in rocks that sample multiple stratigraphic sections; (3) radiometric age dating of units in stratigraphic sections and from key volcanic and impact units; (4) higher-resolution measurements of heat flux, subsurface structure, and magnetic field anomalies coupled with absolute age dating. Understanding the evolution of early Mars will feed forward to understanding the factors driving the divergent evolutionary paths of the Earth, Venus, and thousands of small rocky extra solar planets yet to be discovered.

rocky exoplanets↗
DOE OSTI2024

Fiber Sorbents – A Versatile Platform for Sorption-Based Gas Separations

Increasing demand for high-purity fine chemicals and a drive for process intensification of large-scale separations have driven significant work on the development of highly engineered porous materials with promise for sorption-based separations. While sorptive separations in porous materials offer energy-efficient alternatives to longstanding thermal-based methods, the particulate nature of many of these sorbents has sometimes limited their large-scale deployment in high-throughput applications such as gas separations, for which the necessary high feed flow rates and gas velocities accrue prohibitive operational costs. These processability limitations have been historically addressed through powder shaping methods aimed at the fabrication of structured sorbent contactors based on pellets, beads or monoliths, commonly obtained as extrudates. These structures overcome limitations such as elevated pressure drops commonly recorded across powder adsorption beds but often accrue thermal limitations arising from elevated particle density and aggregation, which ultimately cap their maximum separation performance. Furthermore, the harsh mechanical strain to which powder particles are subjected during contactor fabrication, in the form of extrusion/compression forces, can result in partial pore occlusion and framework degradation, further limiting their performance. Here, we present the development of porous fiber sorbents as an alternative sorbent contactor design capable of addressing sorbent processability limitations while enabling an array of performance-maximizing heat integration capabilities. This new sorbent form factor leverages pre-existing know-how from hollow fiber spinning to produce fiber-shaped sorbent contactors through the phase inversion of known polymers in a process known as dry-jet/wet quenching. The process of phase inversion allows microporous sorbent particles to be latched onto a macroporous polymer matrix under mild processing conditions, thus making it compatible with soft porous materials prone to amorphization under traditional pelletization conditions. Sorbent fibers can be created with different geometries through control of the spinning apparatus and process, offering the possibility to produce monolithic and hollow fibers alike, the latter of which can be integrated with thermalization fluid flows. In this Account, we summarize our progress in the field of fiber sorbents from both design and application standpoints. We further guide the reader through the evolution of this field from the early inceptive work on zeolite hollow fibers to recent developments on MOF fibers. We highlight the versatile nature of fiber sorbents, both from the composition, fabrication and structure points of view, and further demonstrate how fiber sorbents offer alternative paths in tackling new and challenging chemical separation challenges like direct air capture (DAC), with a final perspective on the future of the field.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Liquid Oxygen/Liquid Methane Integrated Power and Propulsion

The proposed paper will cover ongoing work at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) on integrated power and propulsion for advanced human exploration. Specifically, it will present findings of the integrated design, testing, and operational challenges of a liquid oxygen / liquid methane (LOx/LCH4) propulsion brassboard and Solid Oxide Fuel Cell (SOFC) system. Human-Mars architectures point to an oxygen-methane economy utilizing common commodities, scavenged from the planetary atmosphere and soil via In-Situ Resource Utilization (ISRU), and common commodities across sub-systems. Due to the enormous mass gear-ratio required for human exploration beyond low-earth orbit, (for every 1 kg of payload landed on Mars, 226 kg will be required on Earth) increasing commonality between spacecraft subsystems such as power and propulsion can result in tremendous launch mass and volume savings. Historically, propulsion and fuel cell power subsystems have had little interaction outside of the generation (fuel cell) and consumption (propulsion) of electrical power. This was largely due to a mismatch in preferred commodities (hypergolics for propulsion; oxygen & hydrogen for fuel cells). Although this stove-piped approach benefits from simplicity in the design process, it means each subsystem has its own tanks, pressurization system, fluid feed system, etc. increasing overall spacecraft mass and volume. A liquid oxygen / liquid methane commodities architecture across propulsion and power subsystems would enable the use of common tankage and associated pressurization and commodity delivery hardware for both. Furthermore, a spacecraft utilizing integrated power and propulsion could use propellant residuals - propellant which could not be expelled from the tank near depletion due to hydrodynamic considerations caused by large flow demands of a rocket engine - to generate power after all propulsive maneuvers are complete thus utilizing previously wasted mass. Such is the case for human and robotic planetary landers. Although many potential benefits through integrated power & propulsion exist, integrated operations have yet to be successfully demonstrated and many challenges have already been identified the most obvious of which is the large temperature gradient. SOFC chemistry is exothermic with operating temperatures in excess of 1,000 K; however, any shared commodities will be undoubtedly stored at cryogenic temperatures (90-112 K) for mass efficiency reasons. Spacecraft packaging will drive these two subsystems in close proximity thus heat leak into the commodity tankage must be minimized and/or mitigated. Furthermore, commodities must be gasified prior to consumption by the SOFC. Excess heat generated by the SOFC could be used to perform this phase change; however, this has yet to be demonstrated. A further identified challenge is the ability of the SOFC to handle the sudden power spikes created by the propulsion system. A power accumulator (battery) will likely be necessary to handle these sudden demands while the SOFC thermally adjusts. JSC's current SOFC test system consists of a 1 kW fuel cell designed by Delphi. The fuel cell is currently undergoing characterization testing at the NASA JSC Energy Systems Test Area (ESTA) after which a Steam Methane Reformer (SMR) will be integrated and the combined system tested in closed-loop. The propulsion brassboard is approximately the size of what could be flown on a sounding rocket. It consists of one 100 lbf thrust "main" engine developed for NASA by Aerojet and two 10 lbf thrusters to simulate a reaction control system developed at NASA JSC. This system is also under development and initial testing at ESTA. After initial testing, combined testing will occur which will provide data on the fuel cell's ability to sufficiently handle the power spikes created by the propulsion system. These two systems will also be modeled using General-Use Nodal Network Solver (GUNNS) software. Once anchored with test data, this model will be used to extrapolate onto other firing profiles and used to size the power accumulator.

Banker, Brian↗
NASA NTRS2016

CryoCart Restoration and Vacuum Pipe Construction

Propulsion systems that utilize hypergolic propellants have been used to power space vehicles since the beginning of the space program. Liquid methane and oxygen propulsion systems have emerged as an alternative and have proven to be more environmentally friendly. The incorporation of liquid methane/liquid oxygen (LOX) into the propulsion system has demonstrated an increase in engine performance, as well as a reduction in the volume, size and complexity of the system. Consequently, reducing the total mass of the vehicle which is a crucial aspect that is considered when planning space missions to both the Moon and Mars [1]. Project Morpheus has made significant advancements in liquid oxygen/liquid methane propulsion system technologies by incorporating a LOX/methane propulsion system to a vertical test bed. The vehicle consisted of a 5,000 lb main engine and four 20 lb remote control system (RCS) engines that utilize liquid methane/LOX as its propellant [1]. The vehicle completed successful flight testing at Kennedy Space Center in 2014 which marked the completion of the Morpheus project. Subsequent projects utilizing Morpheus' vertical test bed have been developed to make further advancements. One of the subsequent projects consisted of the addition of a smaller 2,000 lb main engine and a cold helium heat exchanger which would make it possible for a pressurant tank systems to be send to Mars or the Moon by significantly decreasing the overall mass and volume of the pressurant tank. The hot fire tests of the integrated system with the smaller main engine and cold helium heat exchanger were successful at sea level, but further studies are being conducted to better understand how the vertical test bed will behave under thermal-vacuum conditions. For this reason, the integrated vehicle will be taken to Plum Brook to be tested in a chamber capable of simulating these conditions. To ensure that the vehicle will function properly under vacuum conditions, testing will be first completed at the component level. During this process, the igniter of the main engine and the RCS thrusters will be tested under a vacuum. To complete the testing of the components, the test setup first needed to be finalized. The CryoCart is being used to feed the propellants to the test article. The CryoCart is a movable test set-up that was developed in 2009 to provide a mobile platform for testing oxygen/methane systems with hot-fire capability up to 100 lbf. The CryoCart consists of three different systems: Oxygen, Methane, and liquid Nitrogen. The Oxygen and Methane systems are placed into two different carts while the liquid nitrogen system is mainly located in the methane cart. Over the years, the CryoCart has been utilized for different projects and has undergone deterioration. For this reason, a new phase has been developed to rebuild it to working conditions once again. During my internship, I was aiding in the construction and restoration of the CryoCart. In the initial stages of the process, I updated the fluid and electrical schematics for the oxygen, methane, and test article systems. The original CryoCart consisted of an electrical panel that utilized electromechanical relays and a terminal to drive the igniter power and signal, as well as the main fuel and oxygen valves. This electrical panel connected to the CryoCart through various wire harnesses that could be found exiting from the CryoCart. First, it was determined how these harnesses connected to the electromechanical relays so that they worked correctly. Once the electrical system was understood, an alternative for the electromechanical relays and the Molex connectors used throughout the system was sought since these components can often prove to be unreliable. Solid State relays and MIL connectors were purchased to serve as replacements. Upon arrival of the parts, crimping and wiring was completed to install the new solid state relays and MIL connectors. During the replacement of the relays and connectors, system checks of the electrical system were ran to ensure that the system was working correctly. While completing system checks, the pressure transducers that were not functioning properly were also replaced and any issue with the wiring or signal was addressed. Once the electrical components were replaced, the restoration of the fluid system began. Parts of the tubing in the CryoCart had to be rebuild and often consisted of sizing, cutting, bending, filing, and sanding the tubing to prepare it to be flared. Many components had to be proof-tested to bring their certifications up to date, and several components had to be replaced. Various flex hoses, valves, and fittings were send to the Clean Lab because they were new, dirty, or had gone through proof-testing. Once they arrived from the cleaning lab they had to be put back to the system and leak checks and functional tests were conducted. In the Nitrogen system, the copper tubing located in the Oxygen cart was rebuild and Aerogel insulation was added to this section. A new gaseous nitrogen system was added to the CryoCart to purge the vacuum tube which will serve as the test chamber. Once the CryoCart was completed, construction of parts of the vacuum tube began. A flange was manufactured with welded fittings to hold the line of the vacuum pump as well as some extra fittings which will serve as extra inlets used to introduce fluid lines to the vacuum tube. Stress analysis was ran in this flange to ensure that it would not fail under vacuum conditions. The fluid lines leading from the air side of the vacuum to the test article were also constructed and added to the mount that had already been manufactured. Three different sets of tubing were constructed to accommodate the seven different RCS thruster and the main engine igniter that are going to be tested. Full electrical system checks were completed to ensure that all the wire harnesses and valves were functioning. Upon the completion of the CryoCart and the vacuum tube, hot fire testing for the RCS thrusters and the main engine igniter are going to begin. During this time any issues encountered with the engines or igniter will be addressed to ensure that the components function under vacuum conditions. After successful completion of testing, the vertical test bed, Morpheus, will be rebuilt and prepared to be sent to Plum Brook. In Plum Brook, the vehicle will be tested in the thermal-vacuum chamber to demonstrate that integrated lox-methane propulsion system operation in space-like conditions. This internship has allowed me the opportunity to gain valuable hands on experience and to develop skills that will aid in my education as well as in the workforce, while at the same time helping me determine that I would like to further pursue a career in propulsion engineering.

Chaidez, Mariana↗
NASA NTRSDate not supplied

NASA's Habitation Development Status: Current Concepts and ISRU Opportunities

Introduction: The National Aeronautics and Space Administration (NASA) is embarking on a bold journey to return humankind to the Moon and onward to Mars with innovative commercial, international, and academic partnerships. Under the Artemis series of missions, NASA seeks to establish sustained human exploration of deep space through an objectives-based approach. This approach drives the identification of needed system functionality and the current and future capabilities which will eventually allow humanity to sustainably live beyond Earth. Providing evolvable and scalable habitation is a cornerstone function that calls for the collection and integration of current, developmental, and future technologies that can meet near-term exploration needs while growing into long-term sustained presence. NASA is advancing in-space habitation through its Next Space Technologies for Exploration Partnerships (NextSTEP) model while designing lunar, Mars transit, and Mars surface habitat government reference concepts for Artemis missions. These efforts have unveiled possible near-term opportunities for the in-space resource utilization community if human habitation is considered a future customer of space resources. NextSTEP Habitation Development: NASA is closely working with commercial partners under its NextSTEP Appendix A model to advance habitation systems in the arena of inflatable and composite habitation structures. Such efforts promise efficiencies in volumetric packaging and overall spacecraft mass respectively. Recent testing by commercial partners have helped to quantify possible failure mechanisms for inflatable structures while advancing their technology towards eventual flight certification. The advancement of such Class II habitation structures, in which the habitat is only fully deployed once in-space or on a planetary surface, is critical to providing increased habitable volume for long-duration missions with no additional mass penalties. The progression of such technology is infused into NASA’s government reference concepts for notional deep space habitation concepts. Current Government Reference Concepts: To best inform the formulation of future collaborative solicitations, NASA employs the practice of internally developing reference concepts for future exploration elements. These concepts aid in identifying the functions and capabilities needed to complete NASA missions as well as feasible solutions within the timeframe needed. Government reference concepts for a lunar Surface Habitat, Mars Transit Habitat, and Mars Sur-face Habitat are continuously being developed and updated to better guide the Agency’s overall exploration architecture. Lunar Surface Habitat. As NASA returns to the Moon, it is evaluating possible lunar surface habitation concepts. The Surface Habitat (SH) reference concept entails a hybrid metallic-inflatable structure capable of initially housing two crew for surface stays of up to 30 days in duration. While initial missions may span ~7 days in duration, consideration is being given to expanding SH’s capability to support a crew of four for up to 60 days over its 15-year design life. Functionally, the SH serves as a ‘hub’ for all Artemis crewed surface operations, providing internal volume for maintenance, medical, logistics, science utilization, and extravehicular activity (EVA) support in addition to core habitation functionality such as environmental control and life support (ECLS) and power generation and distribution among many others. Additionally, NASA has entered a study agreement with the Italian Space Agency (Agenzia Spaziale Italiana – ASI) to investigation a possible Multi-Purpose Habitat (MPH) as an additional or augmenting habit-able element for the lunar surface. Mars Transit Habitat. NASA’s current architectural concept for initial human missions to Mars entails the utilization of a transit habitat (TH) to transport a four-person crew to and from Mars orbit, departing from and returning to a lunar near-rectilinear halo orbit (NRHO), over the course of a ~1,200-day mission. While holding a similar 15-year design lifetime, TH will also support a series of analog mission activities in NRHO to gradually test the systems and interaction with lunar surface elements, some of which may be adapted for Mars surface exploration. Holding similar functional capabilities as SH, TH is sized to support much longer durations in space and greater logistical independence. Mars Surface Habitat. NASA is still exploring the concept of operations for initial crewed missions to Mars. As such, the Mars Surface Habitat (MSH) concept is still in its infancy as options for mobile, pressurized habitation and stationary habitats are being explored. It is expected MSH will leverage heavily from the lunar SH and possible lunar pressurized rover, however the very different Martian environment will likely necessitate modifications. ISRU Opportunities: Despite the advancements under NASA’s NextSTEP habitation work and continually optimized reference concepts, NASA is facing near-term mass and power challenges that may create opportunities to the ISRU community by providing yet another possible customer for space resources. While NASA desires to use regenerative ECLS systems (ECLSS) for all habitation concepts, their operation comes with initial mass penalties and maintenance overheads when compared to simpler open-loop architectures. Because of this, NASA is currently pro-posing an open-loop, consumables-based architecture for its surface habitats to achieve initial launch and delivery lander mass targets while scarring for the in-corporation of regenerative ECLSS to meet longer mission durations and sustained presence. With such an architecture, oxygen and potable water are needed consumables, which initial ISRU systems may be able to provide in a pilot capacity. Although the TH is expecting to utilize regenerative ECLSS, advancements in lunar surface-based ISRU and possible re-supply of spacecraft in lunar or Mars orbit could significantly reduce the logistical need for ECLSS related spares on TH and possibly allow a similar open-loop and consumables-based architecture. In addition to ECLSS mass concerns, the SH is facing challenges with energy storage to support operations over periods of darkness exceeding 100 hours. Both battery and fuel cell-based power architectures are being traded, opening options for external power generation and energy storage. One possibility is ISRU-produced H2 and O2 feeding external primary fuel cell systems which could supplement habitation power generation while reducing initial mass and volume until much more powerful fission power systems might be deployed. Conclusion: Significant advancements are being made in evolvable habitation concepts that span from near-term technologies, such as inflatable structures under NextSTEP, to potentially revolutionary capabilities like the lunar surface construction as funded through the Moon-to-Mars Planetary Autonomous Construction Technologies (MMPACT) project. As NASA investigates both heritage capabilities and rap-idly advancing, disruptive technologies, there are likely many near-term opportunities for initial ISRU capabilities to significantly aid human habitation and increase self-sufficiency beyond Earth.

habitation↗
NASA NTRSDate not supplied

NASA's Habitation Development Status: Current Concepts and ISRU Opportunities

Introduction: The National Aeronautics and Space Administration (NASA) is embarking on a bold journey to return humankind to the Moon and onward to Mars with innovative commercial, international, and academic partnerships [1]. Under the Artemis series of missions, NASA seeks to establish sustained human exploration of deep space through an objectives-based approach [2]. This approach drives the identification of needed system functionality and the current and future capabilities which will eventually allow humanity to sustainably live beyond Earth. Providing evolvable and scalable habitation is a cornerstone function that calls for the collection and integration of current, developmental, and future technologies that can meet near-term exploration needs while growing into long-term sustained presence. NASA is advancing in-space habitation through its Next Space Technologies for Exploration Partnerships (NextSTEP) model while designing lunar, Mars transit, and Mars surface habitat government reference concepts for Artemis missions. These efforts have unveiled possible near-term opportunities for the in-space resource utilization community if human habitation is considered a future customer of space resources. NextSTEP Habitation Development: NASA is closely working with commercial partners under its NextSTEP Appendix A model to advance habitation systems in the arena of inflatable and composite habitation structures. Such efforts promise efficiencies in volumetric packaging and overall spacecraft mass respectively. Recent testing by commercial partners have helped to quantify possible failure mechanisms for inflatable structures while advancing their technology towards eventual flight certification. The advancement of such Class II habitation structures, in which the habitat is only fully deployed once in-space or on a planetary surface [3], is critical to providing increased habitable volume for long-duration missions with no additional mass penalties. The progression of such technology is infused into NASA’s government reference concepts for notional deep space habitation concepts. Current Government Reference Concepts: To best inform the formulation of future collaborative solicitations, NASA employs the practice of internally developing reference concepts for future exploration elements. These concepts aid in identifying the functions and capabilities needed to complete NASA missions as well as feasible solutions within the timeframe needed. Government reference concepts for a lunar Surface Habitat, Mars Transit Habitat, and Mars Sur-face Habitat are continuously being developed and updated to better guide the Agency’s overall exploration architecture. Lunar Surface Habitat. As NASA returns to the Moon, it is evaluating possible lunar surface habitation concepts. The Surface Habitat (SH) reference concept entails a hybrid metallic-inflatable structure capable of initially housing two crew for surface stays of up to 30 days in duration [4]. While initial missions may span ~7 days in duration, consideration is being given to expanding SH’s capability to support a crew of four for up to 60 days over its 15-year design life [5]. Functionally, the SH serves as a ‘hub’ for all Artemis crewed surface operations, providing internal volume for maintenance, medical, logistics, science utilization, and extravehicular activity (EVA) support in addition to core habitation functionality such as environmental control and life support (ECLS) and power generation and distribution among many others. Additionally, NASA has entered a study agreement with the Italian Space Agency (Agenzia Spaziale Italiana – ASI) to investigation a possible Multi-Purpose Habitat (MPH) as an additional or augmenting habit-able element for the lunar surface [6]. Mars Transit Habitat. NASA’s current architectural concept for initial human missions to Mars entails the utilization of a transit habitat (TH) to transport a four-person crew to and from Mars orbit, departing from and returning to a lunar near-rectilinear halo orbit (NRHO), over the course of a ~1,200-day mission [5]. While holding a similar 15-year design lifetime, TH will also support a series of analog mission activities in NRHO to gradually test the systems and interaction with lunar surface elements, some of which may be adapted for Mars surface exploration. Holding similar functional capabilities as SH, TH is sized to support much longer durations in space and greater logistical independence. Mars Surface Habitat. NASA is still exploring the concept of operations for initial crewed missions to Mars. As such, the Mars Surface Habitat (MSH) concept is still in its infancy as options for mobile, pressurized habitation and stationary habitats are being explored. It is expected MSH will leverage heavily from the lunar SH and possible lunar pressurized rover, however the very different Martian environment will likely necessitate modifications. ISRU Opportunities: Despite the advancements under NASA’s NextSTEP habitation work and continually optimized reference concepts, NASA is facing near-term mass and power challenges that may create opportunities to the ISRU community by providing yet another possible customer for space resources. While NASA desires to use regenerative ECLS systems (ECLSS) for all habitation concepts, their operation comes with initial mass penalties and maintenance overheads when compared to simpler open-loop architectures. Because of this, NASA is currently pro-posing an open-loop, consumables-based architecture for its surface habitats to achieve initial launch and delivery lander mass targets while scarring for the in-corporation of regenerative ECLSS to meet longer mission durations and sustained presence. With such an architecture, oxygen and potable water are needed consumables, which initial ISRU systems may be able to provide in a pilot capacity. Although the TH is expecting to utilize regenerative ECLSS, advancements in lunar surface-based ISRU and possible re-supply of spacecraft in lunar or Mars orbit could significantly reduce the logistical need for ECLSS related spares on TH and possibly allow a similar open-loop and consumables-based architecture. Table 1 Notional ECLSS consumables per mission use for SH and TH [5]. SH (28-day) Open Loop: Water (kg) 288 | Oxygen (kg) 30 TH (1110-day) Closed-Loop: Water (kg) 182 | Oxygen (kg) 123 In addition to ECLSS mass concerns, the SH is facing challenges with energy storage to support operations over periods of darkness exceeding 100 hours. Both battery and fuel cell-based power architectures are being traded, opening options for external power generation and energy storage. One possibility is ISRU-produced H2 and O2 feeding external primary fuel cell systems which could supplement habitation power generation while reducing initial mass and volume until much more powerful fission power systems might be deployed. Conclusion: Significant advancements are being made in evolvable habitation concepts that span from near-term technologies, such as inflatable structures under NextSTEP, to potentially revolutionary capabilities like the lunar surface construction as funded through the Moon-to-Mars Planetary Autonomous Construction Technologies (MMPACT) project [7]. As NASA investigates both heritage capabilities and rap-idly advancing, disruptive technologies, there are likely many near-term opportunities for initial ISRU capabilities to significantly aid human habitation and increase self-sufficiency beyond Earth.

habitation↗