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NASA NTRS2017

Safe Haven Configurations for Deep Space Transit Habitats

Throughout the human space flight program there have been instances where systems failures resulting in smoke, fire, and pressure loss have occurred onboard space vehicles, putting crews at risk for loss of mission and loss of life. In most instances the missions have been in Low-Earth-Orbit (LEO) or Earth-Moon vicinity, with access to multiple volumes that could be used to quickly seal off the damaged module or access escape vehicles for return to Earth. For long duration missions beyond LEO, including Mars transit missions of about 1100 days, the mass penalty for multiple volumes and operating in an environment where a quick return will not be possible have been concerns. In 2016, a study was done to investigate a variety of dual pressure vessel configurations for habitats that could protect the crew from these hazards. It was found that with a modest increase in total mass it should be possible to provide significant protection for the crew. Several configurations were considered that either had a small safe haven to provide 30-days to recover, or a full duration safe haven using two equal size pressure vessel volumes. The 30-day safe haven was found to be the simplest, yielding the least total mass impact but still with some risk if recovery is not possible during that timeframe. The full duration safe haven was the most massive option but provided the most robust solution. This paper provides information on the various layouts developed during the study and provides a discussion of the findings for implementing a safe haven in future habitat designs.

Smitherman, David↗

NASA NTRS2017

Safe Haven Configurations for Deep Space Transit Habitats

Throughout the human space flight program there have been instances where smoke, fire, and pressure loss have occurred onboard space vehicles, putting crews at risk for loss of mission and loss of life. In every instance the mission has been in Low-Earth-Orbit (LEO) with access to multiple volumes that could be used to quickly seal off the damaged module or escape vehicles for a quick return to Earth. For long duration space missions beyond LEO, including Mars transit missions of about 1000 days, the mass penalty for multiple volumes has been a concern as has operating in an environment where a quick return will not be possible. In 2016 a study was done to investigate a variety of dual pressure vessel configurations for habitats that could protect the crew from these hazards. It was found that for a modest increase in total mass it should be possible to provide significant protection for the crew. Several configurations were developed that either had a small safe haven to provide 30-days to recover, or a full duration safe haven using two equal size pressure vessel volumes. The 30-day safe haven was found to be the simplest, yielding the least total mass impact but still with some risk if recovery is not possible during that timeframe. The full duration safe haven was the most massive option but provided the most robust solution. This paper provides information on the various layouts considered in the study and provides a discussion of the findings for implementing a safe haven in future habitat designs.

Smitherman, David↗

DOE OSTI2020

Wireless Sensing and Communication Capability from In-Core to a Monitoring Center

Significant cost savings can be made if electrical cables can be replaced by wireless technology in current Nuclear Power Plants (NPP) and in advance reactor designs. Wireless technology can also provide in-core opportunities by significantly reducing the number of penetrations in the pressure vessel, cost and complexity of sensor installation and by increasing the efficiency of current and advanced reactors. Unlike other deployment scenarios for an industrial environment, operators need to have centralized control over all the networks. Centralized control will reduce implementation costs, provide single point control and enable monitoring of network devices, improve security, and enhance connectivity. Micro-sensors that can simultaneously monitor temperature and pressure within a fuel rod inside nuclear reactors will enable preventative actions during abnormal operating conditions. This ability could avert accidents and enable the expedient development of accident tolerant fuels. A novel micro-sensor suite (~ mm) to simultaneously measure multiple parameters such as temperature, strain, pressure, and neutron/gamma flux inside a fuel rod is being developed for use in reactors. The necessary communication architecture is also being developed to transmit measurement signals from the core to the plant's data cloud or control room. A three three-tier strategy has been developed to support wireless transmission of in-core measurements to the control room or to a secure cloud platform for control, analytics, and decision-making purposes. 1. In-core: data signal from in-core to outside of the pressure vessel within the containment building 2. Containment building: data signal from inside to the outside of the containment building and into the balance of the plant network 3. Balance of the plant network: information transmitted to the data cloud and control room This plan presents a wireless sensing and communication system for use within a reactor core and elsewhere. The communication technology is advantageous to compensate for network equipment failures and adverse data transmission conditions. Wireless technology will significantly increase the resiliency of the plants network system. The wireless system naturally provides multiple transmission path capability and data redundancy.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1974

Fracture initiation and propagation in a cylindrical shell containing an initial surface flaw

An attempt is made to provide the necessary analytical tools for the application of two different types of fracture criteria to shell structures. Of particular interest is the problem of fracture propagation and arrest in a cylindrical pressure vessel containing an initial surface flaw. It is assumed that the flaw has the most unfavorable geometry and orientation, namely, it is a crack lying on a meridional plane. Stress intensity factor for a part-through crack, and a surface or internal crack with a fully yielded net ligament are considered. Attention is given to constant delta curves for depressurization studies and to depressurization and crack arrest in pressure vessels.

Erdogan, F.↗

NASA NTRS1993

NASA Lewis advanced IPV nickel-hydrogen technology

Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts. Some of the advancements are as follows: to use 26 percent potassium hydroxide electrolyte to improve cycle life and performance, to modify the state of the art cell design to eliminate identified failure modes and further improve cycle life, and to develop a lightweight nickel electrode to reduce battery mass, hence reduce launch and/or increase satellite payload. A breakthrough in the LEO cycle life of individual pressure vessel nickel-hydrogen battery cells was reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 accelerated LEO cycles at 80 percent DOD compared to 3,500 cycles for cells containing 31 percent KOH. Results of the boiler plate cell tests have been validated at NWSC, Crane, Indiana. Forty-eight ampere-hour flight cells containing 26 and 31 percent KOH have undergone real time LEO cycle life testing at an 80 percent DOD, 10 C. The three cells containing 26 percent KOH failed on the average at cycle 19,500. The three cells containing 31 percent KOH failed on the average at cycle 6,400. Validation testing of NASA Lewis 125 Ah advanced design IPV nickel-hydrogen flight cells is also being conducted at NWSC, Crane, Indiana under a NASA Lewis contract. This consists of characterization, storage, and cycle life testing. There was no capacity degradation after 52 days of storage with the cells in the discharged state, on open circuit, 0 C, and a hydrogen pressure of 14.5 psia. The catalyzed wall wick cells have been cycled for over 22,694 cycles with no cell failures in the continuing test. All three of the non-catalyzed wall wick cells failed (cycles 9,588; 13,900; and 20,575). Cycle life test results of the Fibrex nickel electrode has demonstrated the feasibility of an improved nickel electrode giving a higher specific energy nickel-hydrogen cell. A nickel-hydrogen boiler plate cell using an 80 mil thick, 90 percent porous Fibrex nickel electrode has been cycled for 10,000 cycles at 40 percent DOD.

Smithrick, John J.↗

DOE OSTI2023

A summary of the mechanical properties data developed in FY 2023 by ANL, INL and ORNL to support the data package development for the A709 Code Case

This report provides the status of tensile, creep, fatigue, and creep-fatigue testing to date conducted at Argonne National Laboratory, Idaho National Laboratory, and Oak Ridge National Laboratory to generate the data package required to qualify Alloy 709 in American Society of Mechanical Engineers, Boiler and Pressure Vessel Code, Section III, Division 5. The Division 5 Class A Alloy 709 Code Case requires data generated from a minimum of three commercial heats. Extensive mechanical properties data have been generated on two commercial heats, and some initial test data have been generated from the third commercial heat. The room temperature tensile test results for the three commercial heats met the specification minimum of the American Society of Mechanical Engineers, Boiler and Pressure Vessel Code, Section II, Part A, SA-213/SA-213M for Grade TP310MoCbN (UNS S31025) seamless tubing. These three commercial heats of Alloy 709 are suitable for generating the code case data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1985

Multikilowatt hydrogen-nickel oxide battery system

The potential of the H2-NiO battery for terrestrial applications was assessed. A multicell design approach that differs significantly from the aerospace individual pressure vessel was used. A number of experimental 100-Ah cells were built to evaluate the new design concepts and components. The experimental cells provided the input needed for a multicell battery design. It is found that new multicell H2-NiO battery has a number of potential advantages for aerospace applications such as the manned space station. The advantages are discussed, and a design concept is presented for a multikilowatt battery in a lightweight pressure vessel.

Dunlop, J. D.↗

NASA NTRS2013

Acoustic Emission Analysis Applet (AEAA) Software

NASA Glenn Research and NASA White Sands Test Facility have developed software supporting an automated pressure vessel structural health monitoring (SHM) system based on acoustic emissions (AE). The software, referred to as the Acoustic Emission Analysis Applet (AEAA), provides analysts with a tool that can interrogate data collected on Digital Wave Corp. and Physical Acoustics Corp. software using a wide spectrum of powerful filters and charts. This software can be made to work with any data once the data format is known. The applet will compute basic AE statistics, and statistics as a function of time and pressure (see figure). AEAA provides value added beyond the analysis provided by the respective vendors' analysis software. The software can handle data sets of unlimited size. A wide variety of government and commercial applications could benefit from this technology, notably requalification and usage tests for compressed gas and hydrogen-fueled vehicles. Future enhancements will add features similar to a "check engine" light on a vehicle. Once installed, the system will ultimately be used to alert International Space Station crewmembers to critical structural instabilities, but will have little impact to missions otherwise. Diagnostic information could then be transmitted to experienced technicians on the ground in a timely manner to determine whether pressure vessels have been impacted, are structurally unsound, or can be safely used to complete the mission.

Nichols, Charles T.↗

NASA NTRS2011

Development of Meandering Winding Magnetometer (MWM (Register Trademark)) Eddy Current Sensors for the Health Monitoring, Modeling and Damage Detection of High Temperature Composite Materials

The increased use of high-temperature composite materials in modern and next generation aircraft and spacecraft have led to the need for improved nondestructive evaluation and health monitoring techniques. Such technologies are desirable to improve quality control, damage detection, stress evaluation and temperature measurement capabilities. Novel eddy current sensors and sensor arrays, such as Meandering Winding Magnetometers (MWMs) have provided alternate or complimentary techniques to ultrasound and thermography for both nondestructive evaluation (NDE) and structural health monitoring (SHM). This includes imaging of composite material quality, damage detection and .the monitoring of fiber temperatures and multidirectional stresses. Historically, implementation of MWM technology for the inspection of the Space Shuttle Orbiter Reinforced Carbon-Carbon Composite (RCC) leading edge panels was developed by JENTEK Sensors and was subsequently transitioned by NASA as an operational pre and post flight in-situ inspection at the Kennedy Space Center. A manual scanner, which conformed'automatically to the curvature of the RCC panels was developed and used as a secondary technique if a defect was found during an infrared thermography screening, During a recent proof of concept study on composite overwrapped pressure vessels (COPV's), three different MWM sensors were tested at three orientations to demonstrate the ability of the technology to measure stresses at various fiber orientations and depths. These results showed excellent correlation with actual surface strain gage measurements. Recent advancements of this technology have been made applying MWM sensor technology for scanning COPVs for mechanical damage. This presentation will outline the recent advance~ in the MWM.technology and the development of MWM techniques for NDE and SHM of carbon wra~ped composite overwrapped pressure vessels (COPVs) including the measurement of internal stresses via a surface mounted sensor array. In addition, this paper will outline recent efforts to produce sensors capable of making real-time measurements at temperatures up to 850 C, and discuss previous results demonstrating capability to monitor carbon fiber temperature changes within a composite material.

Russell, Richard↗

NASA NTRS2006

Near Net Manufacturing Using Thin Gage Friction Stir Welding

Friction Stir Welding (FSW) and near net spin forming of FSW aluminumn blanks were investigated for large-scale pressure vessel applications. With a specific focus on very thin gage 2xxx and 7xxx aluminum alloys, the program concentrated on the following: the criteria used for material selection, a potential manufacturing flow, and the effectiveness and associated risks of near net spin forming. Discussion will include the mechanical properties of the friction stir welds and the parent material from before and after the spin forming process. This effort was performed under a NASA Space Exploration initiative focused on increasing the affordability, reliability and performance of pressure vessels larger than 10 ft. diameter.

Takeshita, Jennifer↗

NASA NTRS2003

A Novel Data System for Verification of Internal Parameters of Motor Design

Three major obstacles have limited the amount of information that can be obtained from inside an operating solid rocket motor. The first is a safety issue due to the presence of live propellant interacting with classical, electrical instrumentation. The second is a pressure vessel feed through risk arising from bringing a large number of wires through the rocket motor wall safely. The third is an attachment/protection issue associated with connecting gages to live propellant. Thiokol has developed a highly miniaturized, networked, electrically isolated data system that has safely delivered information from classical, electrical instrumentation (even on the burning propellant surface) to the outside world. This system requires only four wires to deliver 80 channels of data at 2300 samples/second/channel. The feed through leak path risk is massively reduced from the current situation where each gage requires at least three pressure vessel wire penetrations. The external electrical isolation of the system is better than that of the propellant itself. This paper describes the new system.

Smith, Doug↗

NASA NTRS2008

Constellation Architecture Team-Lunar: Lunar Habitat Concepts

This paper will describe lunar habitat concepts that were defined as part of the Constellation Architecture Team-Lunar (CxAT-Lunar) in support of the Vision for Space Exploration. There are many challenges to designing lunar habitats such as mission objectives, launch packaging, lander capability, and risks. Surface habitats are required in support of sustaining human life to meet the mission objectives of lunar exploration, operations, and sustainability. Lunar surface operations consist of crew operations, mission operations, EVA operations, science operations, and logistics operations. Habitats are crewed pressurized vessels that include surface mission operations, science laboratories, living support capabilities, EVA support, logistics, and maintenance facilities. The challenge is to deliver, unload, and deploy self-contained habitats and laboratories to the lunar surface. The CxAT-Lunar surface campaign analysis focused on three primary trade sets of analysis. Trade set one (TS1) investigated sustaining a crew of four for six months with full outpost capability and the ability to perform long surface mission excursions using large mobility systems. Two basic habitat concepts of a hard metallic horizontal cylinder and a larger inflatable torus concept were investigated as options in response to the surface exploration architecture campaign analysis. Figure 1 and 2 depicts the notional outpost configurations for this trade set. Trade set two (TS2) investigated a mobile architecture approach with the campaign focused on early exploration using two small pressurized rovers and a mobile logistics support capability. This exploration concept will not be described in this paper. Trade set three (TS3) investigated delivery of a "core' habitation capability in support of an early outpost that would mature into the TS1 full outpost capability. Three core habitat concepts were defined for this campaign analysis. One with a four port core habitat, another with a 2 port core habitat, and the third investigated leveraging commonality of the lander ascent module and airlock pressure vessel hard shell. The paper will describe an overview of the various habitat concepts and their functionality. The Crew Operations area includes basic crew accommodations such as sleeping, eating, hygiene and stowage. The EVA Operations area includes additional EVA capability beyond the suit-port airlock function such as redundant airlock(s), suit maintenance, spares stowage, and suit stowage. The Logistics Operations area includes the enhanced accommodations for 180 days such as closed loop life support systems hardware, consumable stowage, spares stowage, interconnection to the other Hab units, and a common interface mechanism for future growth and mating to a pressurized rover. The Mission & Science Operations area includes enhanced outpost autonomy such as an IVA glove box, life support, and medical operations.

Toups, Larry↗

NASA NTRS1995

Long life 80Ah standard IPV NiH2 battery cell

A standard Nickel-Hydrogen (NiH2) Individual Pressure Vessel (IPV) battery cell is needed to meet future low cost, high performance mission requirements for NASA, military, and civil space programs. A common or standard cell design has evolved from the heritage of HST, Milstar, and other Air Force Mantech cell designs with substantial flight experience, while incorporating some of the historical COMSAT cell design features described in a previous NASA publication. Key features include slurry process nickel electrodes having high strength, long life and high yield (lower cost), and dual layer zircar separators for improved KOH retention, uniformality, and longer life. The cell design will have a zirconium oxide wall wick inside the pressure vessel to redistribute electrolyte and extend life. The slurry electrode will be 35 mils thick to take advantage of qualified cell mechanical configurations and proven assembly and activation techniques developed by Eagle Picher Industries (EPI) for the Hubble Space Telescope (HST) RNH-90-3 and 'Generic HST' RNH-90-5 cell designs with back-to-back nickel electrodes produced by the dry sinter process. The 80Ah common cell design can be scaled to meet capacity requirements from 60Ah to 100Ah. Producibility, commonality, and long life performance will be enhanced with the robust cell design described herein.

Armantrout, Jon D.↗

NASA NTRS2017

Measuring Surface Bulk Elemental Composition on Venus

The extreme surface environment (462 C, 93 bars pressure) of Venus makes subsurface measurements of its bulk elemental composition extremely challenging. Instruments landed on the surface of Venus must be enclosed in a pressure vessel. The high surface temperatures also require a thermal control system to keep the instrumentation temperatures within their operational range for as long as possible. Since Venus surface probes can currently operate for only a few hours, it is crucial that the lander instrumentation be able to make statistically significant measurements in a short time. An instrument is described that can achieve such a measurement over a volume of thousands of cubic centimeters of material by using high energy penetrating neutron and gamma radiation. The instrument consists of a Pulsed Neutron Generator (PNG) and a Gamma-Ray Spectrometer (GRS). The PNG emits isotropic pulses of 14.1 MeV neutrons that penetrate the pressure vessel walls, the dense atmosphere and the surface rock. The neutrons induce nuclear reactions in the rock to produce gamma rays with energies specific to the element and nuclear process involved. Thus the energies of the detected gamma rays identify the elements present and their intensities provide the abundance of each element. The GRS spectra are analyzed to determine the Venus elemental composition from the spectral signature of individual major, minor, and trace radioactive elements. As a test of such an instrument, a Schlumberger Litho Scanner oil well logging tool was used in a series of experiments at NASA's Goddard Space Flight Center. The Litho Scanner tool was mounted above large (1.8 m x 1.8 m x.9 m) granite and basalt monuments and made a series of one-hour elemental composition measurements in a planar geometry more similar to a planetary lander measurement. Initial analysis of the results shows good agreement with target elemental assays

Venus↗

NASA NTRS1995

The 50 Ah NiH2 CPV qualification tests

In 1992, the Naval Research Laboratory (NRL) started a program to qualify a large diameter common pressure vessel (CPV) nickel-hydrogen (NiH2) batteries for use on future Navy/NRL spacecraft electrical power subsystems. NRL's involvement with the qualification of CPV NiH2 batteries dates back to 1988 when COMSAT and Johnson Controls, Inc. initiated a joint effort to fly the first ever NiH2 CPV in space. A later NRL-JCI cooperative research and development agreement led to the launch of a space experiment in 1993 and to the use of a single NiH2 CPV battery on the BMDO Clementine spacecraft in 1994. NRL initiated procurement of two, 50 Ah CPV NiH2 batteries in the Fall of 1992. The two batteries were delivered to NRL in June 1994. NiH2 CPV batteries have almost 2x the specific energy (Wh/kg) of nickel cadium batteries and 2x the energy density (Wh/l) of individual pressure vessel NiH2 CPV's. This presentation discusses the results of electrical and mechanical qualification tests conducted at NRL. The tests included electrical characterization, standard capacity, random vibration, peak load, and thermal vacuum. The last slides of the presentation show initial results from the life cycle tests of the second NiH2 CPV battery at 40% depth of discharge and a temperature of 10 C.

Garner, J. C.↗

NASA NTRS2008

High Performance COPVs for In-Space Storage of High Pressure Cryogenic Fuels

Polymeric composite overwrapped pressure vessels (COPVs) provide an attractive material system to support developing commercial launch business and alternate fuel ventures. However to be able to design with these materials, the mechanical behavior of the materials must be understood with regards to processing, performance, damage tolerance, and environment. For the storage of cryogenic propellants, it is important to evaluate the materials performance and impact damage resistance at cryogenic temperatures in order to minimize weight and to ensure safety and reliability. As part of this study, material tests of candidate fiber and resin systems were used as the basis for the selection of the material combinations for evaluation in a COPV at cryogenic conditions. This comprehensive approach has also been expanded to address issues with impact damage tolerance and material degradation due to environmental factors. KEY WORDS: Cryogenic testing, evaluation and applications for pressure vessels, COPVs, tanks, or storage vessels.

Schneider, Judy↗

NASA NTRS1991

Demonstration of Hazardous Hypervelocity Test Capability

NASA Johnson Space Center (JSC) White Sands Test Facility (WSTF) participated in a joint test program with NASA JSC Hypervelocity Impact Research Laboratory (HIRL) to determine if JSC was capable of performing hypervelocity impact tests on hazardous targets. Seven pressurized vessels were evaluated under hypervelocity impact conditions. The vessels were tested with various combinations of liquids and gasses at various pressures. Results from the evaluation showed that vessels containing 100-percent pressurized gas sustained more severe damage and had a higher potential for damaging nearby equipment, than vessels containing 75-percent liquid, 25-percent inert pressurized gas. Two water-filled test vessels, one of which was placed behind an aluminum shield, failed by bulging and splitting open at the impact point; pressure was relieved without the vessel fragmenting or sustaining internal damage. An additional water-filled test vessel, placed a greater distance behind an aluminum shield, sustained damage that resembled a shotgun blast, but did not bulge or split open; again, pressure was relieved without the vessel fragmenting. Two test vessels containing volatile liquids (nitro methane and hydrazine) also failed by bulging and splitting open; neither liquid detonated under hypervelocity test conditions. A test vessel containing nitrogen gas failed by relieving pressure through a circular entry hole; multiple small penetrations opposite the point of entry provided high velocity target debris to surrounding objects. A high-pressure oxygen test vessel fragmented upon impact; the ensuing fire and high velocity fragments caused secondary damage to surrounding objects. The results from the evaluation of the pressurized vessels indicated that JSC is capable of performing hypervelocity impact tests on hazardous targets.

Rodriquez, Karen M.↗

NASA NTRS2017

Strain Monitoring of Flexible Structures

One of the biggest challenges facing NASA's deep space exploration goals is structural mass. A long duration transit vehicle on a journey to Mars, for example, requires a large internal volume for cargo, supplies and crew support. As with all space structures, a large pressure vessel is not enough. The vehicle also requires thermal, micro-meteoroid, and radiation protection, a navigation and control system, a propulsion system, and a power system, etc. As vehicles get larger, their associated systems also get larger and more complex. These vehicles require larger lift capacities and force the mission to become extremely costly. In order to build large volume habitable vehicles, with only minimal increases in launch volume and mass, NASA is developing lightweight structures. Lightweight structures are made from non-metallic materials including graphite composites and high strength fabrics and could provide similar or better structural capability than metals, but with significant launch volume and mass savings. Fabric structures specifically, have been worked by NASA off and on since its inception, but most notably in the 1990's with the TransHAB program. These TransHAB developed structures use a layered material approach to form a pressure vessel with integrated thermal and micro-meteoroid and orbital debris (MMOD) protection. The flexible fabrics allow the vessel to be packed in a small volume during launch and expand into a much larger volume once in orbit. NASA and Bigelow Aerospace recently installed the first human-rated inflatable module on the International Space Station (ISS), known as the Bigelow Expandable Activity Module (BEAM) in May of 2016. The module provides a similar internal volume to that of an Orbital ATK Cygnus cargo vehicle, but with a 77% launch volume savings. As lightweight structures are developed, testing methods are vital to understanding their behavior and validating analytical models. Common techniques can be applied to fabric materials, such as tensile testing, fatigue testing, and shear testing, but common measurement techniques cannot be used on fabric. Measuring strain in a material and during a test is a critical parameter for an engineer to monitor the structure during the test and correlate to an analytical model. The ability to measure strain in fabric structures is a challenge for NASA. Foil strain gauges, for example, are commonplace on metallic structures testing, but are extremely difficult to interface with a fabric substrate. New strain measuring techniques need to be developed for use with fabric structures. This paper investigates options for measuring strain in fabric structures for both ground testing and in-space structural health monitoring. It evaluates current commercially available options and outlines development work underway to build custom measurement solutions for NASA's fabric structures.

Litteken, Douglas A.↗