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Technology Applications that Support Space Exploration

Several enabling technologies have been identified that would provide significant benefits for future space exploration. In-Space demonstrations should be chosen so that these technologies will have a timely opportunity to improve efficiencies and reduce risks for future spaceflight. An early window exists to conduct ground and flight demonstrations that make use of existing assets that were developed for the Space Shuttle and the Constellation programs. The work could be mostly performed using residual program civil servants, existing facilities and current commercial launch capabilities. Partnering these abilities with the emerging commercial sector, along with other government agencies, academia and with international partners would provide an affordable and timely approach to get the launch costs down for these payloads, while increasing the derived benefits to a larger community. There is a wide scope of varied technologies that are being considered to help future space exploration. However, the cost and schedule would be prohibitive to demonstrate all these in the near term. Determining which technologies would yield the best return in meeting our future space needs is critical to building an achievable Space Architecture that allows exploration beyond Low Earth Orbit. The best mix of technologies is clearly to be based on our future needs, but also must take into account the availability of existing assets and supporting partners. Selecting those technologies that have complimentary applications will provide the most knowledge, with reasonable cost, for future use The plan is to develop those applications that not only mature the technology but actually perform a useful task or mission. These might include such functions as satellite servicing, a propulsion stage, processing lunar regolith, generating and transmitting solar power, cryogenic fluid transfer and storage and artificial gravity. Applications have been selected for assessment for future consideration and are addressed in this paper. These applications have been made available to the various NASA study groups that are determining the next steps the Agency must take to secure a sound foundation for future space exploration The paper also addresses how follow-on demonstrations, as launch performance grows, can build on the earlier applications to provide increased benefits for both the commercial and scientific communities. The architecture of incrementally building upon previous successes and insights dramatically lowers the overall associated risk for developing and maturing the key enabling technologies. The goal is to establish a potential business case that encourages commercial activity, thereby reducing the cost for the demonstration while using the technology maturation in developing readiness for future space exploration with overall less risk.

Henderson, Edward M.↗

Development, Build and Certification of the Alternate Fecal Canister (AFC) Hardware for the NASA Exploration Toilet

On longer range exploration missions, the mass and volume of critical hardware and consumables that will be needed to support crew will pose a big stowage challenge. This includes the hardware needed for the collection and storage of human metabolic waste. The amount of stowage needed for this hardware both before (empty) and after (full) use will be a significant burden on the overall spacecraft habitable volume, layout, and design. To help with this challenge, the National Aeronautics and Space Administration (NASA) has developed a collapsible canister for the collection and containment of fecal deposits. The Alternate Fecal Canister (AFC) is an alternative to the exploration toilet hard-sided fecal canister. The AFC is collapsible in its empty state which is a volume benefit to smaller vehicles on longer missions. In addition, the use of lighter-weight materials provides a reduction in mass of the overall container. This paper will provide a summary of the AFC design including final flight design and build, acceptance and qualification testing completed, final certification and delivery and forward plans for a technology demonstration with the exploration toilet on the International Space Station (ISS). In addition, a summary of issues and final resolution encountered during flight build and testing will also be provided. As part of the acceptance and certification process for AFC, the hardware was also put into several rounds of odor testing with the support of the White Sands Test Facility (WSTF). The details, planning and anomalies identified during odor testing will also be summarized in this paper. Finally, a brief overview of potential future design upgrades including changes to address any crew feedback from the ISS demonstration will be discussed.

Fecal Canister↗

Development, Build and Certification of the Alternate Fecal Canister (AFC) Hardware for the NASA Exploration Toilet

On longer range exploration missions, the mass and volume of critical hardware and consumables that will be needed to support crew will pose a big stowage challenge. This includes the hardware needed for the collection and storage of human metabolic waste. The amount of stowage needed for this hardware both before (empty) and after (full) use will be a significant burden on the overall spacecraft habitable volume, layout, and design. To help with this challenge, the National Aeronautics and Space Administration (NASA) has developed a collapsible canister for the collection and containment of fecal deposits. The Alternate Fecal Canister (AFC) is an alternative to the exploration toilet hard-sided fecal canister. The AFC is collapsible in its empty state which is a volume benefit to smaller vehicles on longer missions. In addition, the use of lighter-weight materials provides a reduction in mass of the overall container. This paper will provide a summary of the AFC design including final flight design and build, acceptance and qualification testing completed, final certification and delivery and forward plans for a technology demonstration with the exploration toilet on the International Space Station (ISS). In addition, a summary of issues and final resolution encountered during flight build and testing will also be provided. As part of the acceptance and certification process for AFC, the hardware was also put into several rounds of odor testing with the support of the White Sands Test Facility (WSTF). The details, planning and anomalies identified during odor testing will also be summarized in this paper. Finally, a brief overview of potential future design upgrades including changes to address any crew feedback from the ISS demonstration will be discussed.

Fecal Canister↗

Development, Build and Certification of the Alternate Fecal Canister (AFC) Hardware for the NASA Exploration Toilet

On longer range exploration missions, the mass and volume of critical hardware and consumables that will be needed to support crew will pose a big stowage challenge. This includes the hardware needed for the collection and storage of human metabolic waste. The amount of stowage needed for this hardware both before (empty) and after (full) use will be a significant burden on the overall spacecraft habitable volume, layout, and design. To help with this challenge, the National Aeronautics and Space Administration (NASA) has developed a collapsible canister for the collection and containment of fecal deposits. The Alternate Fecal Canister (AFC) is an alternative to the exploration toilet hard-sided fecal canister. The AFC is collapsible in its empty state which is a volume benefit to smaller vehicles on longer missions. In addition, the use of lighter-weight materials provides a reduction in mass of the overall container. This paper will provide a summary of the AFC design including final flight design and build, acceptance and qualification testing completed, final certification and delivery and forward plans for a technology demonstration with the exploration toilet on the International Space Station (ISS). In addition, a summary of issues and final resolution encountered during flight build and testing will also be provided. As part of the acceptance and certification process for AFC, the hardware was also put into several rounds of odor testing with the support of the White Sands Test Facility (WSTF). The details, planning and anomalies identified during odor testing will also be summarized in this paper. Finally, a brief overview of potential future design upgrades including changes to address any crew feedback from the ISS demonstration will be discussed.

Fecal Canister↗

Viscoelastic characterization of thin-film polymers exposed to low Earth orbit

The materials made available through the Long Duration Exposure Facility (LDEF) satellite provide a set of specimens that can be well characterized and have a known exposure history with reference to atomic oxygen and ultraviolet radiation exposure. Mechanical characteristics measured from control samples and exposed samples provide a data base for predicting the behavior of polymers in low earth orbit. Samples of 1.0 mil thick low density polyethylene were exposed to the low earth orbit environment for a period of six years. These materials were not directly exposed to ram atomic oxygen and offer a unique opportunity for measuring the effect of atomic oxygen and UV radiation on mechanical properties with little concern to the effect of erosion. The viscoelastic characteristics of these materials were measured and compared to the viscoelastic characteristics of control samples. To aid in differentiating the effects of changes in crystallinity resulting from thermal cycling, from the effects of changes in chemical structure resulting from atomic oxygen/UV attack to the polymer, a second set of control specimens, annealed to increase crystallinity, were measured as well. The resulting characterization of these materials will offer insight into the impact of atomic oxygen/UV on the mechanical properties of polymeric materials. The viscoelastic properties measured for the control, annealed, and exposed specimens were the storage and loss modulus as a function of frequency and temperature. From these datum is calculated the viscoelastic master curve derived using the principle of time/temperature superposition. Using the master curve, the relaxation modulus is calculated using the method of Ninomiya and Ferry. The viscoelastic master curve and the stress relaxation modulus provide a direct measure of the changes in the chemical or morphological structure. In addition, the effect of these changes on long-term and short-term mechanical properties is known directly. It should be noted that the dependence on directionality for the polymer films was considered since these films were manufactured by a blown-film process.

Letton, Alan↗

Ultrahigh Areal Capacity Holey Graphene Air Cathodes for Li-O2 and Li-CO2 Batteries

Advanced lithium (Li) batteries using gaseous cathode reactants such as oxygen (O2) and carbon dioxide (CO2)are attractive energy storage platforms because the gases are obtained externally and thus not accounted for in the total battery weight when fully charged.The discharge products at the cathode, typically Li2O2 for Li-O2 batteries and Li2CO3 for Li-CO2 batteries, are insoluble in the electrolyte.Therefore, in order for such batteries to function properly, an “air cathode”,which is a conductive scaffold within the battery cell,is required as a physical location for cathode electrochemical reactions to occur. Prior research has identified many carbon nanomaterials such as carbon nanotubes and graphene as viable choices for air cathode scaffold, while various metallic and metal-free catalytic systems integrated onto carbon-based air cathodes have been developed to improve the sluggish discharge and charge reactions. For future practical applications, the air cathode must exhibit a usable capacity per unit electrode area, or areal capacity, a critical parameter that has been largely overlooked so far in this field. In order to achieve high areal capacity, the air cathode must exhibit a sufficient amount of accessible void volume per unit electrode area while maintaining the conductive scaffold integrity during the entire electrochemical process. Here we present an ultrathick,holey graphene-based air cathode platform fabricated from a facile dry compression process that exhibits remarkable areal capacity values. Holey graphene is a carbon nanomaterial derived from graphene, but with nanometer sized holes through the nanosheet thickness.The presence of these holes enhances mass transport through electrode thickness and also enables the unique dry-press fabrication process that is not achievable using other carbon scaffold materials.The dry-pressed holey graphene air cathode platform is not only compatible with catalyst incorporation to improve battery reaction kinetics, but also allows for novel engineering of electrode architectures that is not achievable using conventional electrode fabrication approaches.The applications of such highly versatile, ultrahigh areal capacity air cathode platforms to both Li-O2 and Li-CO2 battery chemistries will be discussed.

Li-O2 batteries, Li-CO2 batteries, holey graphene,↗

Overview of the High Performance Antiproton (HiPAT) Experiment

The annihilation of matter with antimatter represents the highest energy density of any known reaction, producing 10(exp 8) MJ/g, approximately 10 orders of magnitude more energy per unit mass than chemical based combustion. To take the first step towards using this energy for propulsion applications the NASA MSFC Propulsion Research Center (PRC) has initiated a research activity examining the storage of low energy antiprotons. Storage was identified as a key enabling technology since it builds the experience base necessary to understand the handling of antiprotons for virtually all utilization and high-density storage concepts. To address this need, a device referred to as the High Performance Antiproton Trap (HiPAT) is under development at the NASA MSFC PRC. The HiPAT is an electromagnetic system (Penning-Malmberg design) consisting of a 4 Tesla superconductor, a high voltage confinement electrode system (operation up to 20 KV), and an ultra high vacuum test section (operating in the 10(exp -12) torr range). The system was designed to be portable with an ultimate goal of maintaining 10(exp 12) charged particles with a half-life of 18 days. Currently, this system is being experimentally evaluated using normal matter ions which are cheap to produce and relatively easy to handle. These normal ions provide a good indication of overall trap behavior, with the exception of assessing annihilation losses. The ions are produced external to HiPAT using two hydrogen ion sources, with adjustable beam energy and current. Ion are transported in a beam line and controlled through the use of electrostatic optics. These optics serve to both focus and gate the incoming ions, providing microsecond-timed pulses that are dynamically captured by cycling the HiPAT electric containment field like a 'trap door'. The layout of this system more closely simulates the operations expected at an actual antiproton production facility where 'packets' of antiprotons with pulse widths measured in 100's of nanoseconds could be provided. Initial dynamic capture experiments have been performed with both trap and ton source system functioning at approximately 10% of maximum levels, minimizing the potential for extraneous effects. Dynamic trapping techniques demonstrated the successful capture of millions of hydrogen ions with good agreement with the predicted loading based on the timing sequence, trap electric field, and ion beam current. These techniques will be expanded to examine multiple shot capture or 'stacking' to increase the total number of ions stored within HiPAT.

Martin, James J.↗

Lightning Hazards to Aircraft Fuel Tanks

The hazards of lightning strokes to aircraft fuel tanks have been investigated in artificial-lightning-generation facilities specifically constructed to duplicate closely the natural lightning discharges to air­ craft determined through flight research programs and analysis of lightning-damaged aircraft over a period of many years. Explosion studies were made in an environmental explosion chamber using small fuel tanks under various simulated flight conditions. The results showed that there is a primary hazard whenever there is direct puncture of the fuel-tank wall, whereas the ignition of fuel by hot spots on tank walls due to lightning strikes is unlikely. Punctures of fuel-tank walls by artificial-lightning discharges produced explosions of the fuel in the mixture range from excessively lean to rich mixtures. None of the aluminum alloys, 0.081 inch thick or over, were punctured by the laboratory discharges representative of natural-lightning discharges to aircraft; however, reliance on this wall thickness for complete pro­tection would not be justified, because occasional strokes are known to be of greater magnitude and because statistics reveal variations in the damage pattern. Data gathered by the Lightning and Transients Research Institute on lightning strokes to aircraft show that 90 percent of the strokes recorded have occurred in the temperature range of -10° to +10° C, where many of the jet fuels are flammable but where aviation gasoline is overrich. Also, 10 percent of the strokes recorded have been to the wings, which are the principal fuel-storage areas for modern aircraft. Thus, there is a hazard, particularly for jet fuels. Certain protective measures are indicated by the studies to date, such as the use of lightning diverter rods, thickening of the wing skin in areas near the most probable stroke paths, and the use of fuel-tank liners in critical areas.

Robb, J. D.↗

Solar White Thermal Coating for Cryogenic Propulsion Systems

NASA is currently conducting research into the potential of storing cryogenic fluid in low Earth orbit (LEO). Having cryogenic propellant readily available for high-performance propulsion systems can be very beneficial for deep space missions in the near future. One of the key challenges to storing cryogenic fluid in LEO is minimizing boil-off. To address the challenge, NASA is evaluating new concepts in thermal insulation. One recent experimental study evaluated the feasibility of using Yttrium Oxide (Y2O3), formed into tiles or spray coating that can potentially be used as a thermal coating for cryogenic propellant storage applications in deep space. Due to its temperature and wavelength dependent optical properties, this “solar white” material can reflect a vast majority of the Sun’s radiative energy while having a very high infrared emissivity for rejecting heat to deep space. As a part of the material development and proof of concept testing, multiple tests have been run at KSC and GRC to demonstrate the performance of the material. At GRC, the tests were run using the Deep Space Solar Simulator (DS3) which contains a thermal vacuum chamber in which the solar white sample was exposed to a deep space environment (< 10 K, optically dense walls) while under full illumination via solar lamp. In order to improve the use of the test results and apply them to spacecraft, there is a need to be able to model the material properties within NASA’s standard thermal modeling tools. As such, it was set out to verify a thermal model of one of the experiments using Thermal Desktop with Sinda. The thermal model of the DS3 test setup includes the solar white sample along with a solar lamp simulator capable of outputting heat at varying wavelengths. The model was developed in order to validate the test results and also to help predict results that will be obtained in future tests. This paper will review the modeling methods and thermal analysis results for various test cases that were run within the DS3 facility.

Cryogenic↗

Modeling Separate and Combined Atmospheres in BIO-Plex

We modeled BIO-Plex designs with separate or combined atmospheres and then simulated controlling the atmosphere composition. The BIO-Plex is the Bioregenerative Planetary Life Support Systems Test Complex, a large regenerative life support test facility under development at NASA Johnson Space Center. Although plants grow better at above-normal carbon dioxide levels, humans can tolerate even higher carbon dioxide levels. Incinerator exhaust has very high levels of carbon dioxide. An elaborate BIO-Plex design would maintain different atmospheres in the crew and plant chambers and isolate the incinerator exhaust in the airlock. This design easily controls the crew and plant carbon dioxide levels but it uses many gas processors, buffers, and controllers. If all the crew's food is grown inside BIO-Plex, all the carbon dioxide required by the plants is supplied by crew respiration and the incineration of plant and food waste. Because the oxygen mass flow must balance in a closed loop, the plants supply all the oxygen required by the crew and the incinerator. Using plants for air revitalization allows using fewer gas processors, buffers, and controllers. In the simplest design, a single combined atmosphere was used for the crew, the plant chamber, and the incinerator. All gas processors, buffers, and controllers were eliminated. The carbon dioxide levels were necessarily similar for the crew and plants. If most of the food is grown, carbon dioxide can be controlled at the desired level by scheduling incineration. An intermediate design uses one atmosphere for the crew and incinerator chambers and a second for the plant chamber. This allows different carbon dioxide levels for the crew and plants. Better control of the atmosphere is obtained by varying the incineration rate. Less gas processing storage and control is needed if more food is grown.

Jones, Harry↗

Modeling Separate and Combined Atmospheres in BIO-Plex

We modeled BIO-Plex designs with separate or combined atmospheres and then simulated controlling the atmosphere composition. The BIO-Plex is the Bioregenerative Planetary Life Support Systems Test Complex, a large regenerative life support test facility under development at NASA Johnson Space Center. Although plants grow better at above-normal carbon dioxide levels, humans can tolerate even higher carbon dioxide levels. incinerator exhaust has very high levels of carbon dioxide. An elaborate BIO-Plex design would maintain different atmospheres in the crew and plant chambers and isolate the incinerator exhaust in the airlock. This design easily controls the crew and plant carbon dioxide levels but it uses many gas processors, buffers, and controllers. If all the crew's food is grown inside BIO-Plex, all the carbon dioxide required by the plants is supplied by crew respiration and the incineration of plant and food waste. Because the oxygen mass flow must balance in a closed loop, the plants supply all the oxygen required by the crew and the incinerator. Using plants for air revitalization allows using fewer gas processors, buffers, and controllers. In the simplest design, a single combined atmosphere was used for the crew, the plant chamber, and the incinerator. All gas processors, buffers, and controllers were eliminated. The carbon dioxide levels were necessarily similar for the crew and plants. If most of the food is grown, carbon dioxide can be controlled at the desired level by scheduling incineration. An intermediate design uses one atmosphere for the crew and incinerator chambers and a second for the plant chamber. This allows different carbon dioxide levels for the crew and plants. Better control of the atmosphere is obtained by varying the incineration rate. Less gas processing, storage, and control is needed if more food is grown.

Jones, Harry↗

Comparison of Carbon Dioxide and Helium as Fire Extinguishing Agents for Spacecraft

The effects of radiation heat transfer in microgravity compared to convection heat transfer in earth gravity for opposed-flow (downward) over thermally-thick fuel using low density foam fuel were investigated. Microgravity experiments on flame spread over thermally-thick fuels were conducted using foam fuels to obtain low density and thermal conductivity, and thus large flame spread rate compared to dense fuels such as PMMA. And thereby valid microgravity results were obtained even in 2.2 second drop-tower experiments not to mention for the longer duration tests in Zero Gravity Facility. Contrast to the conventional understanding, it was found that steady flame spread can occur over thick fuels in quiescent microgravity environments, especially when radiatively-active diluent gases such as CO2 were employed. This is proposed to result from radiative heat transfer from the flame to the fuel surface, which could lead to steady spread even when the amount of the heat transfer via conduction from the flame to the fuel bed is negligible. Radiative effects are more significant at microgravity conditions because the flame is thicker and thus the volume of radiating combustion products is larger as well. These results suggested that helium may be a better inert or extinguishment agent on both a mass and a mole bases at microgravity even though CO2 is much better on a mole bases at earth gravity, and these are relevant to studies of fire safety in manned spacecraft, particularly the International Space Station that uses CO2 fire extinguishers. CO2 may not be as effective as an extinguishing agent at g as it is at earth gravity in some conditions because of the differences in spread mechanisms between the two cases. In particular, the difference between conduction-dominated heat transport to the fuel bed at earth gravity and radiation-dominated heat transport at g indicates that radiatively-inert diluent such as helium could be preferable in g applications. Helium may be a superior fire suppression agent at g on several bases. First, helium is more effective than CO2 on a mole basis (thus pressure times storage volume basis) at g, meaning that the size and weight of storage bottles would be smaller for the same fire-fighting capability. Second; helium is much more effective on a mass basis (by about 11 times) at g. Third; helium has no physiological activity, unlike CO2 that affects human respiration. Fourth, as compared to N2 or CO2, is not very soluble in water and thus has fewer tendencies to cause bloodstream bubble formation following rapid spacecraft cabin depressurization.

Gokoglu, Suleyman↗

Comparison of Carbon Dioxide and Helium as Fire Extinguishing Agents for Spacecraft

The effects of radiation heat transfer in microgravity compared to convection heat transfer in earth gravity for opposed-flow (downward) over thermally-thick fuel using low density foam fuel were investigated. Microgravity experiments on flame spread over thermally-thick fuels were conducted using foam fuels to obtain low density and thermal conductivity, and thus large flame spread rate compared to dense fuels such as PMMA. And thereby valid microgravity results were obtained even in 2.2 second drop-tower experiments not to mention for the longer duration tests in Zero Gravity Facility. Contrast to the conventional understanding, it was found that steady flame spread can occur over thick fuels in quiescent microgravity environments, especially when radiatively-active diluent gases such as CO2 were employed. This is proposed to result from radiative heat transfer from the flame to the fuel surface, which could lead to steady spread even when the amount of the heat transfer via conduction from the flame to the fuel bed is negligible. Radiative effects are more significant at microgravity conditions because the flame is thicker and thus the volume of radiating combustion products is larger as well. These results suggested that helium may be a better inert or extinguishment agent on both a mass and a mole bases at microgravity even though CO2 is much better on a mole bases at earth gravity, and these are relevant to studies of fire safety in manned spacecraft, particularly the International Space Station that uses CO2 fire extinguishers. CO2 may not be as effective as an extinguishing agent at microgravity as it is at earth gravity in some conditions because of the differences in spread mechanisms between the two cases. In particular, the difference between conduction-dominated heat transport to the fuel bed at earth gravity and radiation-dominated heat transport at microgravity indicates that radiatively-inert diluent such as helium could be preferable in microgravity applications. Helium may be a superior fire suppression agent at microgravity on several bases. First, helium is more effective than CO2 on a mole basis (thus pressure times storage volume basis) at microgravity, meaning that the size and weight of storage bottles would be smaller for the same fire-fighting capability. Second; helium is much more effective on a mass basis (by about 11 times) at microgravity. Third; helium has no physiological activity, unlike CO2 that affects human respiration. Fourth, as compared to N2 or CO2, is not very soluble in water and thus has fewer tendencies to cause bloodstream bubble formation following rapid spacecraft cabin depressurization.

Gokoglu, Suleyman↗

Validation of Cryogenic Propellant Tank Self-Pressurization

NASA’s near-future long-term space missions necessitate advancements in cryogenic fluid management (CFM), which includes safe and reliable long-term propellant storage. Consequently, NASA STMD (Space Technology Mission Directorate) has established the CFM Portfolio Project to improve CFM technologies for upcoming missions. As a part of CFM Modeling Portfolio, NASA Marshall Space Flight Center’s (MSFC) Fluid Dynamics branch within the Propulsion Systems Department is tasked with assessing and improving computational tools used to support flight projects such as Human Lander System and Commercial Lunar Payload Services. One of the challenging modeling problems is that of self-pressurization of propellant tank due to heat leakage over long time periods. Reduced order and nodal tools find it extremely difficult to accurately predict self-pressurization under transient conditions or where complex flow patterns or thermal gradients exist, and application of 3-D CFD (computational fluid dynamics) simulations is necessary to characterize these problems. Until recently, CFD simulations for these long-term processes (order of hours or days) have been too impractical to conduct due to prohibitive wall time and computational resource requirements. The requisite CFD tool need to be efficient, computationally scalable, modular with ability to incorporate various physics models, and robust enough to not accumulate conservation errors over several hours of simulated time. NASA MSFC’s Loci-Stream CFD tool along with the VOF module is a great candidate to fit this mold. In this paper, we validate Loci-Stream for predicting self-pressurization of a flight scale propellant tank so it can serve as a reliable design and analysis tool for NASA’s CFM application needs. Liquid hydrogen tank pressurization tests carried out at the K-site testing facility provide a reliable data set for this purpose. These tests were simulated using Loci-Stream solver with VOF module as well as a hybrid approach which uses a lumped model for the ullage gas domain and CFD simulation of the liquid propellant. Both are shown to have very good predictive capabilities over multiple K-site experiments.

Hong Q. Yang↗

Validation of Cryogenic Propellant Tank Self-Pressurization

NASA's near-future long-term space missions necessitate advancements in cryogenic fluid management (CFM), which includes safe and reliable long-term propellant storage. Consequently, NASA STMD (Space Technology Mission Directorate) has established the CFM Portfolio Project to improve CFM technologies for upcoming missions. As a part of CFM Modeling Portfolio, NASA Marshall Space Flight Center's (MSFC) Fluid Dynamics branch within the Propulsion Systems Department is tasked with assessing and improving computational tools used to support flight projects such as Human Lander System and Commercial Lunar Payload Services. One of the challenging modeling problems is that of self-pressurization of propellant tank due to heat leakage over long time periods. Reduced order and nodal tools find it extremely difficult to accurately predict self-pressurization under transient conditions or where complex flow patterns or thermal gradients exist, and application of 3-D CFD (computational fluid dynamics) simulations is necessary to characterize these problems. Until recently, CFD simulations for these long-term processes (order of hours or days) have been too impractical to conduct due to prohibitive wall time and computational resource requirements. The requisite CFD tool need to be efficient, computationally scalable, modular with ability to incorporate various physics models, and robust enough to not accumulate conservation errors over several hours of simulated time. NASA MSFC's Loci-Stream CFD tool along with the VOF module is a great candidate to fit this mold. In this paper, we validate Loci-Stream for predicting self-pressurization of a flight scale propellant tank so it can serve as a reliable design and analysis tool for NASA's CFM application needs. Liquid hydrogen tank pressurization tests carried out at the K-site testing facility provide a reliable data set for this purpose. These tests were simulated using Loci-Stream solver with VOF module as well as a hybrid approach which uses a lumped model for the ullage gas domain and CFD simulation of the liquid propellant. Both are shown to have very good predictive capabilities over multiple K-site experiments.

cryogenic fluid management↗

Development of Low-Cost Micromanipulation Systems for Small Extraterrestrial Samples

The analysis of microscale to mm-scale astromaterials often involves the transfer of samples from storage or collection substrates to analytical substrates. These transfers are accomplished by hand (via tweezers or fine-tipped needles) or by utilizing micromanipulation instruments. Freehand manipulation of small particles is extremely challenging due to involuntary hand tremors on the order of 100μm and due to the triboelectric charging induced by frequent contact between the manipulation tool and the support substrate. Months or years of practice may be required before an investigator develops the necessary experience to confidently transfer a 10-20μm particle in this manner. Handling even mm-sized particles with fine-tipped tweezers can be challenging, due to the inability to precisely control the force with which grains are being held. Mechanical, hydraulic, and motorized/electrical micromanipulators enable the precise handling of microscale samples and are often utilized in laboratories where frequent small sample preparation is required. However, the price of such instruments (~ $10,000 to $100,000) makes them cost-prohibitive for some institutions. Graduate students or early-career scientists interested in conducting research on interplanetary dust particles, Itokawa particles returned by Hayabusa, or future samples returned by OSIRIS-REx or Hayabusa2 may experience difficulty in justifying the expense of a micromanipulator to their advisors or principle investigators. Johnson Space Center’s Astromaterials Acquisition and Curation Office and the Lunar and Planetary Institute conduct annual training for early career scientists and for investigators that require experience with handling of small extraterrestrial samples. In support of this training, we have been developing low-cost mechanical alternatives to expensive micromanipulators that training participants can implement in their respective facilities.

Snead, Christopher J.↗

Modeling ARRM Xenon Tank Pressurization Using 1D Thermodynamic and Heat Transfer Equations

As a first step in understanding what ground support equipment (GSE) is required to provide external cooling during the loading of 5,000 kg of xenon into 4 aluminum lined composite overwrapped pressure vessels (COPVs), a modeling analysis was performed using Microsoft Excel. The goals of the analysis were to predict xenon temperature and pressure throughout loading at the launch facility, estimate the time required to load one tank, and to get an early estimate of what provisions for cooling xenon might be needed while the tanks are being filled. The model uses the governing thermodynamic and heat transfer equations to achieve these goals. Results indicate that a single tank can be loaded in about 15 hours with reasonable external coolant requirements. The model developed in this study was successfully validated against flight and test data. The first data set is from the Dawn mission which also utilizes solar electric propulsion with xenon propellant, and the second is test data from the rapid loading of a hydrogen cylindrical COPV. The main benefit of this type of model is that the governing physical equations using bulk fluid solid temperatures can provide a quick and accurate estimate of the state of the propellant throughout loading which is much cheaper in terms of computational time and licensing costs than a Computation Fluid Dynamics (CFD) analysis while capturing the majority of the thermodynamics and heat transfer.

Xenon storage↗

Network-Capable Application Process and Wireless Intelligent Sensors for ISHM

Intelligent sensor technology and systems are increasingly becoming attractive means to serve as frameworks for intelligent rocket test facilities with embedded intelligent sensor elements, distributed data acquisition elements, and onboard data acquisition elements. Networked intelligent processors enable users and systems integrators to automatically configure their measurement automation systems for analog sensors. NASA and leading sensor vendors are working together to apply the IEEE 1451 standard for adding plug-and-play capabilities for wireless analog transducers through the use of a Transducer Electronic Data Sheet (TEDS) in order to simplify sensor setup, use, and maintenance, to automatically obtain calibration data, and to eliminate manual data entry and error. A TEDS contains the critical information needed by an instrument or measurement system to identify, characterize, interface, and properly use the signal from an analog sensor. A TEDS is deployed for a sensor in one of two ways. First, the TEDS can reside in embedded, nonvolatile memory (typically flash memory) within the intelligent processor. Second, a virtual TEDS can exist as a separate file, downloadable from the Internet. This concept of virtual TEDS extends the benefits of the standardized TEDS to legacy sensors and applications where the embedded memory is not available. An HTML-based user interface provides a visual tool to interface with those distributed sensors that a TEDS is associated with, to automate the sensor management process. Implementing and deploying the IEEE 1451.1-based Network-Capable Application Process (NCAP) can achieve support for intelligent process in Integrated Systems Health Management (ISHM) for the purpose of monitoring, detection of anomalies, diagnosis of causes of anomalies, prediction of future anomalies, mitigation to maintain operability, and integrated awareness of system health by the operator. It can also support local data collection and storage. This invention enables wide-area sensing and employs numerous globally distributed sensing devices that observe the physical world through the existing sensor network. This innovation enables distributed storage, distributed processing, distributed intelligence, and the availability of DiaK (Data, Information, and Knowledge) to any element as needed. It also enables the simultaneous execution of multiple processes, and represents models that contribute to the determination of the condition and health of each element in the system. The NCAP (intelligent process) can configure data-collection and filtering processes in reaction to sensed data, allowing it to decide when and how to adapt collection and processing with regard to sophisticated analysis of data derived from multiple sensors. The user will be able to view the sensing device network as a single unit that supports a high-level query language. Each query would be able to operate over data collected from across the global sensor network just as a search query encompasses millions of Web pages. The sensor web can preserve ubiquitous information access between the querier and the queried data. Pervasive monitoring of the physical world raises significant data and privacy concerns. This innovation enables different authorities to control portions of the sensing infrastructure, and sensor service authors may wish to compose services across authority boundaries.

Figueroa, Fernando↗