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At least 55 records · Page 3

Oxygen production by pyrolysis of lunar regolith

Oxygen was identified as the most important product of initial lunar materials processing efforts. A source of oxygen on the Moon provides an alternative to the costly transport of propellant to the Moon or to low earth orbit. Pyrolysis, or vapor-phase reduction, involves heating a feedstock to temperatures sufficient to decompose the constituent metal oxides and release oxygen. The process relies on the vaporization of metal oxides in the form of reduced suboxides or atomic species. The reduced species must then be condensed without re-oxidizing, yielding oxygen in the gas phase. The feasibility of obtaining oxygen from common lunar minerals was demonstrated using solar furnace experiments. These results are discussed together with chemical equilibrium models which were extended to include the multicomponent oxides used in experiments. For the first time, both experiments and theoretical models dealt with the complex oxides that make up potential lunar feedstocks. Two major conclusions are drawn from this preliminary work. First, unbeneficiated regolith is a suitable feedstock for pyrolysis. Second, the process can operate at moderate temperatures, circa 2000 K, which could be supplied by direct solar or electrical energy. In addition to these advantages in choice of feedstock and energy source, the pyrolysis process requires no chemicals or reagents, making it an attractive process for lunar oxygen production.

Senior, Constance L.↗

Cold Metal Transfer (CMT) Wire-Arc Additive Manufacturing (WAAM)

Aluminum has been identified as a compound within regolith and is likely to become a core component of our infrastructure on the lunar surface as in-situ resource utilization (ISRU) capabilities are advanced Large-scale components, outfitting, and repairs of aluminum materials can be fabricated with robotic wire arc additive manufacturing (WAAM) in order to inhabit the moon’s surface long term WAAM is a high value process for lunar advanced manufacturing as it does not require special containment to reduce explosion hazards such as powder-based additive processes and feedstock The welding process of cold metal transfer (CMT) is a relatively new variation of gas metal arc welding (GMAW, also known as MIG) that relies on the detection of a short circuit in the welding process to control the deposition droplet action, resulting in lower heat input and splatter compared to conventional MIG welding The past year was spent developing the CMT-WAAM process for aluminum materials, tested specialty feedstock, tested within the high vacuum environment, and advanced the MSFC capability to perform complex toolpathing from solid models Upcoming and future work includes large depositions working towards material certification for multiple feedstocks, in-situ monitoring, work to use recycled materials for the AM feedstock, and the design and fabrication of a parabolic flight experiment payload.

cold metal transfer↗

Short-Term Elevated Temperature Mechanical Performance and Microstructure of A Niobium-Zirconium Alloy Produced via Laser Powder Bed Fusion In-Situ Alloying

Nb-1Zr is a readily fabricable, dispersion-strengthened niobium alloy with improved elevated temperature properties compared to commercially pure niobium. This low to moderate strength niobium alloy is desirable in thermal management systems for fission power and propulsion applications; however, pre-alloyed spherical feedstock for powder-based additive manufacturing processes is generally unavailable. Laser powder bed fusion (L-PBF) in-situ alloying of a Nb-1Zr chemistry was performed using a high-purity niobium feedstock coated with 1 wt% of zirconium-based ceramic compound nano-powders: ZrO 2 , ZrC, and ZrH 2 . The additively manufactured material was mechanically tested at elevated temperatures within a controlled environment in the as-built condition. For comparison, traditionally manufactured wrought feedstock was also tested within an identical environment. Examination of the materials’ microstructure and short-term elevated temperature mechanical response determined: in-situ alloying of spherical Nb powder feedstock with Zr-based ceramic nanoparticles can be successfully implemented; the ZrO 2 addition offered the greatest elevated temperature stability and strength but exhibited brittle behavior; the ZrC addition achieved a balance of room temperature ductility and elevated temperature strength; and the ZrH 2 -modified material had the lowest as-built interstitial content and showed high ductility with mechanical performance most similar to wrought Nb-1Zr.

Niobium Alloy↗

Vapor diffusion electrode improves fuel cell operation

Vapor diffusion type fuel cell electrode presents a nonwetting barrier to the liquid feedstocks so they may contact the electrolyte only in the vapor state. Thus, it effects feedstock mixing with the electrolyte at the electrolyte/catalyst interface but prevents feedstock decomposition and catalyst poisoning from liquid mingling.

Smith, J. O.↗

Silicon Solar Cell Process Development, Fabrication and Analysis

Ribbon to Ribbon (RTR) solar cells processed from polycrystalline feedstock showed maximum AMO efficiency of 5.6%. Solar cells from single crystalline feedstock showed slightly higher efficiency than those from polycrystalline feedstock, indicating maximum efficiency of about 6.6% with SiO AR coating. Single crystalline control cells gave 11-12% AMO efficiencies demonstrating that the poor performance of the RTR solar was due to the low quality of material itself. Dendritic web solar cells from the standard process showed maximum AMO efficiency of 9.8% while efficiency of control solar cells were around 11-12%. Web solar cells from back surface field (BSF) process indicated maximum AMO efficiency of 10.9%. Some improvement in open circuit voltage was noticed from the BSF process. Small light spot scanning experiments were carried out on the solar cells from Wacker Silso, EFG, RTR, and dendritic web ribbons. Photoresponse results provided information on localized cell performance and grain size in polycrystalline material, and agreed quite well with the cell performance data, such as efficiency, minority carrier diffusion length, and spectral response.

Yoo, H. I.↗

A study of industrial hydrogen and syngas supply systems

The potential and incentives required for supplying hydrogen and syngas feedstocks to the U.S. chemical industry from coal gasification systems were evaluated. Future hydrogen and syngas demand for chemical manufacture was estimated by geographic area and projected economics for hydrogen and syngas manufacture was estimated with geographic area of manufacture and plant size as parameters. Natural gas, oil and coal feedstocks were considered. Problem areas presently affecting the commercial feasibility of coal gasification discussed include the impact of potential process improvements, factors involved in financing coal gasification plants, regulatory barriers affecting coal gasification, coal mining/transportation, air quality regulations, and competitive feedstock pricing barriers. The potential for making coal gasification the least costly H2 and syngas supply option. Options to stimulate coal gasification system development are discussed.

Amos, W. J.↗

Hybrid fuel cell/diesel generation total energy system, part 2

Meeting the Goldstone Deep Space Communications Complex (DGSCC) electrical and thermal requirements with the existing system was compared with using fuel cells. Fuel cell technology selection was based on a 1985 time frame for installation. The most cost-effective fuel feedstock for fuel cell application was identified. Fuels considered included diesel oil, natural gas, methanol and coal. These fuel feedstocks were considered not only on the cost and efficiency of the fuel conversion process, but also on complexity and integration of the fuel processor on system operation and thermal energy availability. After a review of fuel processor technology, catalytic steam reformer technology was selected based on the ease of integration and the economics of hydrogen production. The phosphoric acid fuel cell was selected for application at the GDSCC due to its commercial readiness for near term application. Fuel cell systems were analyzed for both natural gas and methanol feedstock. The subsequent economic analysis indicated that a natural gas fueled system was the most cost effective of the cases analyzed.

Blazek, C. F.↗

On using a pyroclastic deposit as a manned lunar base site

Hawke et al. (1990) suggest that ilmenite found in Apollo 17-type pyroclastic glass may provide feedstock for the hydrogen reduction of ilmenite process for producing lunar oxygen. They also suggest that the ilmenite may help retain solar wind hydrogen and helium which can be extracted for use at a lunar outpost or even transported back to Earth for fusion fuel in the case of helium-3. Therefore, they suggest that ilmenite-rich material may be the best candidate. Here, researchers propose a somewhat different approach. They propose that the pyroclastic glass can be reduced directly to produce oxygen and one or more metals. Sulfur would be another important byproduct of the processing. This process would eliminate the need for having specific minerals such as ilmenite or for doing any mineral concentration. The bulk pyroclastic would provide the feedstock. Some recent experiments at the Johnson Space Center suggest that an iron-rich composition would be the most suitable for this direct feedstock reduction and that the titanium content may not be important. Also, the lunar pyroclastic deposits would be extremely useful in constructing and supporting a lunar base.

Coombs, Cassandra R.↗

Beneficiation of lunar rocks and regolith - Concepts and difficulties

Some of the inherent differences between lunar rocks and the finer portion of the regolith, the soil, are discussed. A brief outline of the formation of lunar soil is presented. Beneficiation of rocks vs regolith for the production of an ilmenite feedstock is addressed in particular, but the concepts and principles considered are applicable to other situations as well. The overall systems design must take the range of available feedstocks into account. Decisions on design that will influence feedstock requirements must be made.

Taylor, Lawrence A.↗

Development of a Prototype Low-Voltage Electron Beam Freeform Fabrication System

NASA's Langley Research Center and Johnson Space Center are developing a solid freeform fabrication system utilizing an electron beam energy source and wire feedstock. This system will serve as a testbed for exploring the influence of gravitational acceleration on the deposition process and will be a simplified prototype for future systems that may be deployed during long-duration space missions for assembly, fabrication, and production of structural and mechanical replacement components. Critical attributes for this system are compactness, minimal mass, efficiency in use of feedstock material, energy use efficiency, and safety. The use of a low-voltage (less than 15kV) electron beam energy source will reduce radiation so that massive shielding is not required to protect adjacent personnel. Feedstock efficiency will be optimized by use of wire, and energy use efficiency will be achieved by use of the electron beam energy source. This system will be evaluated in a microgravity environment using the NASA KC-135A aircraft.

Watson, J. K.↗

Solid Freeform Fabrication: An Enabling Technology for Future Space Missions

The emerging class of direct manufacturing processes known as Solid Freeform Fabrication (SFF) employs a focused energy beam and metal feedstock to build structural parts directly from computer aided design (CAD) data. Some variations on existing SFF techniques have potential for application in space for a variety of different missions. This paper will focus on three different applications ranging from near to far term to demonstrate the widespread potential of this technology for space-based applications. One application is the on-orbit construction of large space structures, on the order of tens of meters to a kilometer in size. Such structures are too large to launch intact even in a deployable design; their extreme size necessitates assembly or erection of such structures in space. A low-earth orbiting satellite with a SFF system employing a high-energy beam for high deposition rates could be employed to construct large space structures using feedstock launched from Earth. A second potential application is a small, multifunctional system that could be used by astronauts on long-duration human exploration missions to manufacture spare parts. Supportability of human exploration missions is essential, and a SFF system would provide flexibility in the ability to repair or fabricate any part that may be damaged or broken during the mission. The system envisioned would also have machining and welding capabilities to increase its utility on a mission where mass and volume are extremely limited. A third example of an SFF application in space is a miniaturized automated system for structural health monitoring and repair. If damage is detected using a low power beam scan, the beam power can be increased to perform repairs within the spacecraft or satellite structure without the requirement of human interaction or commands. Due to low gravity environment for all of these applications, wire feedstock is preferred to powder from a containment, handling, and safety standpoint. The energy beams may be either electron beam or laser, and the developments required for either energy source to achieve success in these applications will be discussed.

Taminger, Karen M. B.↗

Autonomous In-Situ Resources Prospector

This presentation will describe the concept of an autonomous, intelligent, rover-based rapid surveying system to identify and map several key lunar resources to optimize their ISRU (In Situ Resource Utilization) extraction potential. Prior to an extraction phase for any target resource, ground-based surveys are needed to provide confirmation of remote observation, to quantify and map their 3-D distribution, and to locate optimal extraction sites (e.g. ore bodies) with precision to maximize their economic benefit. The system will search for and quantify optimal minerals for oxygen production feedstock, water ice, and high glass-content regolith that can be used for building materials. These are targeted because of their utility and because they are, or are likely to be, variable in quantity over spatial scales accessible to a rover (i.e., few km). Oxygen has benefits for life support systems and as an oxidizer for propellants. Water is a key resource for sustainable exploration, with utility for life support, propellants, and other industrial processes. High glass-content regolith has utility as a feedstock for building materials as it readily sinters upon heating into a cohesive matrix more readily than other regolith materials or crystalline basalts. Lunar glasses are also a potential feedstock for oxygen production, as many are rich in iron and titanium oxides that are optimal for oxygen extraction. To accomplish this task, a system of sensors and decision-making algorithms for an autonomous prospecting rover is described. One set of sensors will be located in the wheel tread of the robotic search vehicle providing contact sensor data on regolith composition. Another set of instruments will be housed on the platform of the rover, including VIS-NIR imagers and spectrometers, both for far-field context and near-field characterization of the regolith in the immediate vicinity of the rover. Also included in the sensor suite are a neutron spectrometer, ground-penetrating radar, and an instrumented cone penetrometer for subsurface assessment. Output from these sensors will be evaluated autonomously in real-time by decision-making software to evaluate if any of the targeted resources has been detected, and if so, to quantify their abundance. Algorithms for optimizing the mapping strategy based on target resource abundance and distribution are also included in the autonomous software. This approach emphasizes on-the-fly survey measurements to enable efficient and rapid prospecting of large areas, which will improve the economics of ISRU system approaches. The mature technology will enable autonomous rovers to create in-situ resource maps of lunar or other planetary surfaces, which will facilitate human and robotic exploration.

Dissly, R. W.↗

Notes on Lithology, Mineralogy, and Production for Lunar Simulants

The creation of lunar simulants requires a very broad range of specialized knowledge and information. This document covers several topic areas relevant to lithology, mineralogy, and processing of feedstock materials that are necessary components of the NASA lunar simulant effort. The naming schemes used for both terrestrial and lunar igneous rocks are discussed. The conflict between the International Union of Geological Sciences standard and lunar geology is noted. The rock types known as impactites are introduced. The discussion of lithology is followed by a brief synopsis of pyroxene, plagioclase, and olivine, which are the major mineral constituents of the lunar crust. The remainder of the text addresses processing of materials, particularly the need for separation of feedstock minerals. To illustrate this need, the text includes descriptions of two norite feedstocks for lunar simulants: the Stillwater Complex in Montana, United States, and the Bushveld Complex in South Africa. Magnetic mineral separations, completed by Hazen Research, Inc. and Eriez Manufacturing Co. for the simulant task, are discussed.

Rickman, D. L.↗

NASA's GreenLab Research Facility: A Guide for a Self-Sustainable Renewable Energy Ecosystem

There is a large gap between the production and demand for energy from alternative fuel and alternative renewable energy sources. The sustainability of humanity, as we know it, directly depends on the ability to secure affordable fuel, food, and freshwater. NASA Glenn Research Center (Glenn) has initiated a laboratory pilot study on using biofuels as viable alternative fuel resources for the field of aviation, as well as utilizing wind and solar technology as alternative renewable energy resources. The GreenLab Research Facility focuses on optimizing biomass feedstock using algae and halophytes as the next generation of renewable aviation fuels. The unique approach in this facility helps achieve optimal biomass feedstock through climatic adaptation of balanced ecosystems that do not use freshwater, compete with food crops, or use arable land. In addition, the GreenLab Research Facility is powered, in part, by alternative and renewable energy sources, reducing the major environmental impact of present electricity sources. The ultimate goal is to have a 100 percent clean energy laboratory that, when combined with biomass feedstock research, has the framework in place for a self-sustainable renewable energy ecosystem that can be duplicated anywhere in the world and can potentially be used to mitigate the shortage of food, fuel, and water. This paper describes the GreenLab Research Facility at Glenn and its power and energy sources, and provides recommendations for worldwide expansion and adoption of the facility s concept.

Bomani, B. M. McDowell↗

Centrifugal Sieve for Gravity-Level-Independent Size Segregation of Granular Materials

Conventional size segregation or screening in batch mode, using stacked vibrated screens, is often a time-consuming process. Utilization of centrifugal force instead of gravity as the primary body force can significantly shorten the time to segregate feedstock into a set of different-sized fractions. Likewise, under reduced gravity or microgravity, a centrifugal sieve system would function as well as it does terrestrially. When vibratory and mechanical blade sieving screens designed for terrestrial conditions were tested under lunar gravity conditions, they did not function well. The centrifugal sieving design of this technology overcomes the issues that prevented sieves designed for terrestrial conditions from functioning under reduced gravity. These sieves feature a rotating outer (cylindrical or conical) screen wall, rotating fast enough for the centrifugal forces near the wall to hold granular material against the rotating screen. Conventional centrifugal sieves have a stationary screen and rapidly rotating blades that shear the granular solid near the stationary screen, and effect the sieving process assisted by the airflow inside the unit. The centrifugal sieves of this new design may (or may not) have an inner blade or blades, moving relative to the rotating wall screen. Some continuous flow embodiments would have no inner auger or blades, but achieve axial motion through vibration. In all cases, the shearing action is gentler than conventional centrifugal sieves, which have very high velocity differences between the stationary outer screen and the rapidly rotating blades. The new design does not depend on airflow in the sieving unit, so it will function just as well in vacuum as in air. One advantage of the innovation for batch sieving is that a batch-mode centrifugal sieve may accomplish the same sieving operation in much less time than a conventional stacked set of vibrated screens (which utilize gravity as the primary driving force for size separation). In continuous mode, the centrifugal sieves can provide steady streams of fine and coarse material separated from a mixed feedstock flow stream. The centrifugal sieves can be scaled to any desired size and/or mass flow rate. Thus, they could be made in sizes suitable for small robotic exploratory missions, or for semi-permanent processing of regolith for extraction of volatiles of minerals. An advantage of the continuous-mode system is that it can be made with absolutely no gravity flow components for feeding material into, or for extracting the separated size streams from, the centrifugal sieve. Thus, the system is capable of functioning in a true microgravity environment. Another advantage of the continuous-mode system is that some embodiments of the innovation have no internal blades or vanes, and thus, can be designed to handle a very wide range of feedstock sizes, including occasional very large oversized pieces, without jamming or seizing up.

Walton, Otis R.↗

3D Printing in Zero-G Experiment, In Space Manufacturing (LPS, 4)

The 3D Printing in Zero‐G Experiment has been an ongoing effort for several years. In June 2014 the technology demonstration 3D printer was launched to the International Space Station. In November 2014 the first 21 parts were manufactured in orbit marking the beginning of a paradigm shift that will allow astronauts to be more self‐sufficient and pave the way to larger scale orbital manufacturing. Prior to launch the 21 parts were built on the ground with the flight unit with the same feedstock. These ground control samples are to be tested alongside the flight samples in order to determine if there is a measurable difference between parts built on the ground vs. parts built in space. As of this writing, testing has not yet commenced. Tests to be performed are structured light scanning for volume and geometric discrepancies, CT scanning for density measurement, destructive testing of mechanical samples, and SEM analysis for inter‐laminar adhesion discrepancies. Additionally, an ABS material characterization was performed on mechanical samples built from the same CAD files as the flight and ground samples on different machine / feedstock combinations. The purpose of this testing was twofold: first to obtain mechanical data in order to have a baseline comparison for the flight and ground samples and second to ascertain if there is a measurable difference between machines and feedstock.

Bean, Quincy↗

In-Space Recycler Technology Demonstration

In 2014, a 3D printer was installed and used successfully on the International Space Station (ISS), creating the first additively manufactured part in space. While additive manufacturing is a game changing technology for exploration missions, the process still requires raw feedstock material to fabricate parts. Without a recycling capability, a large supply of feedstock would need to be stored onboard, which negates the logistical benefits of these capabilities. Tethers Unlimited, Inc. (TUI), received a Small Business Innovation Research (SBIR) award to design and build the first In-space Recycler for demonstration aboard the ISS in 2017. To fully test this technology in microgravity, parts will be 3D printed, recycled into reusable filament, and then reprinted into new parts. Recycling scrap into printer filament is quite challenging in that a recycler must be able to handle a large variety of possible scrap configurations and densities. New challenges include: dealing with inevitable contamination of the scrap material, minimizing damage to the molecular structure of the plastic during reprocessing, managing a larger volume of hot liquid plastic, and exercising greater control over the cooling/resolidification of the material. TUI has developed an architecture that addresses these challenges by combining standard, proven technologies with novel, patented processes developed through this effort. Results show that the filament diameter achieved is more consistent than commercial filament, with only minimal degradation of material properties over recycling steps. In May 2016, TUI completed fabrication of a flight prototype, which will ultimately progress to the demonstration unit for the ISS as a testbed for future exploration missions. This capability will provide significant cost savings by reducing the launch mass and volume required for printer feedstock as well as reduce waste that must be stored or disposed.

Recycling↗

Freeform Deposition Method for Coolant Channel Closeout

A method is provided for fabricating a coolant channel closeout jacket on a structure having coolant channels formed in an outer surface thereof. A line of tangency relative to the outer surface is defined for each point on the outer surface. Linear rows of a metal feedstock are directed towards and deposited on the outer surface of the structure as a beam of weld energy is directed to the metal feedstock so-deposited. A first angle between the metal feedstock so-directed and the line of tangency is maintained in a range of 20-90.degree.. The beam is directed towards a portion of the linear rows such that less than 30% of the cross-sectional area of the beam impinges on a currently-deposited one of the linear rows. A second angle between the beam and the line of tangency is maintained in a range of 5-65 degrees.

Gradl, Paul R.↗