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All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

International Space Station (ISS) Emergency Mask (EM) Development

The Emergency Mask (EM) is considered a secondary response emergency Personal Protective Equipment (PPE) designed to provide respiratory protection to the International Space Station (ISS) crewmembers in response to a post-fire event or ammonia leak. The EM is planned to be delivered to ISS in 2012 to replace the current air purifying respirator (APR) onboard ISS called the Ammonia Respirator (AR). The EM is a one ]size ]fits ]all model designed to fit any size crewmember, unlike the APR on ISS, and uses either two Fire Cartridges (FCs) or two Commercial Off-the-Shelf (COTS) 3M(Trademark). Ammonia Cartridges (ACs) to provide the crew with a minimum of 8 hours of respiratory protection with appropriate cartridge swap ]out. The EM is designed for a single exposure event, for either post ]fire or ammonia, and is a passive device that cannot help crewmembers who cannot breathe on their own. The EM fs primary and only seal is around the wearer fs neck to prevent a crewmember from inhaling contaminants. During the development of the ISS Emergency Mask, several design challenges were faced that focused around manufacturing a leak free mask. The description of those challenges are broadly discussed but focuses on one key design challenge area: bonding EPDM gasket material to Gore(Registered Trademark) fabric hood.

Toon, Katherine P.↗
NASA NTRS2011

An Evaluation of Ultra-High Pressure Regulator for Robotic Lunar Landing Spacecraft

The Robotic Lunar Lander Development (RLLD) Project Office at NASA Marshall Space Flight Center (MSFC) has studied several lunar surface science mission concepts. These missions focus on spacecraft carrying multiple science instruments and power systems that will allow extended operations on the lunar surface. Initial trade studies of launch vehicle options for these mission concepts indicate that the spacecraft design will be significantly mass-constrained. To minimize mass and facilitate efficient packaging, the notional propulsion system for these landers has a baseline of an ultra-high pressure (10,000 psig) helium pressurization system that has been used on Defense missiles. The qualified regulator is capable of short duration use; however, the hardware has not been previously tested at NASA spacecraft requirements with longer duration. Hence, technical risks exist in using this missile-based propulsion component for spacecraft applications. A 10,000-psig helium pressure regulator test activity is being carried out as part of risk reduction testing for MSFC RLLD project. The goal of the test activity is to assess the feasibility of commercial off-the-shelf ultra-high pressure regulator by testing with a representative flight mission profile. Slam-start, gas blowdown, water expulsion, lock-up, and leak tests are also performed on the regulator to assess performance under various operating conditions. The preliminary test results indicated that the regulator can regulate helium to a stable outlet pressure of 740 psig within the +/- 5% tolerance band and maintain a lock-up pressure less than +5% for all tests conducted. Numerous leak tests demonstrated leakage less than 10-3 standard cubic centimeters per second (SCCS) for internal seat leakage at lock-up and less than10-5 SCCS for external leakage through the regulator ambient reference cavity. The successful tests have shown the potential for 10,000 psig helium systems in NASA spacecraft and have reduced risk associated with hardware availability and hardware ability to meet RLL mission requirements.

Burnside, Christopher↗
NASA NTRS2011

Interstage Flammability Analysis Approach

The Interstage of the Ares I launch platform houses several key components which are on standby during First Stage operation: the Reaction Control System (ReCS), the Upper Stage (US) Thrust Vector Control (TVC) and the J-2X with the Main Propulsion System (MPS) propellant feed system. Therefore potentially dangerous leaks of propellants could develop. The Interstage leaks analysis addresses the concerns of localized mixing of hydrogen and oxygen gases to produce deflagration zones in the Interstage of the Ares I launch vehicle during First Stage operation. This report details the approach taken to accomplish the analysis. Specified leakage profiles and actual flammability results are not presented due to proprietary and security restrictions. The interior volume formed by the Interstage walls, bounding interfaces with the Upper and First Stages, and surrounding the J2-X engine was modeled using Loci-CHEM to assess the potential for flammable gas mixtures to develop during First Stage operations. The transient analysis included a derived flammability indicator based on mixture ratios to maintain achievable simulation times. Validation of results was based on a comparison to Interstage pressure profiles outlined in prior NASA studies. The approach proved useful in the bounding of flammability risk in supporting program hazard reviews.

Little, Jeffrey K.↗
NASA NTRS2012

Floating Oil-Spill Containment Device

Previous oil containment booms have an open top that allows natural gas to escape, and have significant oil leakage due to wave action. Also, a subsea pyramid oil trap exists, but cannot move relative to moving oil plumes from deepsea oil leaks. The solution is to have large, moveable oil traps. One version floats on the sea surface and has a flexible tarp cover and a lower weighted skirt to completely entrap the floating oil and natural gas. The device must have at least three sides with boats pulling at each apex, and sonar or other system to track the slowly moving oil plume, so that the boats can properly locate the booms. The oil trap device must also have a means for removal of the oil and the natural gas. A second design version has a flexible pyramid cover that is attached by lines to ballast on the ocean floor. This is similar to fixed, metal pyramid oil capture devices in the Santa Barbara Channel off the coast of California. The ballast lines for the improved design, however, would have winches that can move the pyramid to always be located above the oil and gas plume. A third design is a combination of the first two. It uses a submerged pyramid to trap oil, but has no anchor and uses boats to locate the trap. It has ballast weights located along the bottom of the tarp and/or at the corners of the trap. The improved floating oil-spill containment device has a large floating boom and weighted skirt surrounding the oil and gas entrapment area. The device is triangular (or more than three sides) and has a flexible tarp cover with a raised gas vent area. Boats pull on the apex of the triangles to maintain tension and to allow the device to move to optimum locations to trap oil and gas. The gas is retrieved from a higher buoyant part of the tarp, and oil is retrieved from the floating oil layer contained in the device. These devices can be operated in relatively severe weather, since waves will break over the devices without causing oil leaking. Also, natural gas is entrapped and can be retrieved. All designs can use sonar to locate the moving oil plume, and then be relocated by using boats or winches to move the oil trapping devices. These devices can be constructed of treated, non-permeable DuPont Kevlar cloth (or similar material).

Jones, Jack A.↗
NASA NTRS2011

Issues of Long-Term Cryogenic Propellant Storage in Microgravity

Modern multi-layer insulation (MLI) allows to sharply reduce the heat leak into cryogenic propellant storage tanks through the tank surface and, as a consequence, significantly extend the storage duration. In this situation the MLI penetrations, such as support struts, feed lines, etc., become one of the most significant challenges of the tanks heat management. This problem is especially acute for liquid hydrogen (LH2) storage, since currently no efficient cryocoolers exist that operate at very low LH2 temperatures (20K). Even small heat leaks under microgravity conditions and over the period of many months give rise to a complex slowly-developing, large-scale spatiotemporal physical phenomena in a multi-phase liquid-vapor mixture. These phenomena are not well-understood nor can be easily controlled. They can be of a potentially hazardous nature for long-term on-orbital cryogenic torage, propellant loading, tank chilldown, engine restart, and other in-space cryogenic fluid management operations. To support the engineering design solutions that would mitigate these effects a detailed physics-based analysis of heat transfer, vapor bubble formation, growth, motion, coalescence and collapse is required in the presence of stirring jets of different configurations and passive cooling devices such as MLI, thermodynamic vent system, and vapor-cooled shield. To develop physics-based models and correlations reliable for microgravity conditions and long-time scales there is a need for new fundamental data to be collected from on-orbit cryogenic storage experiments. Our report discusses some of these physical phenomena and the design requirements and future studies necessary for their mitigation. Special attention is payed to the phenomena occurring near MLI penetrations.

Muratov, C. B.↗
NASA NTRS2012

Pressure Dome for High-Pressure Electrolyzer

A high-strength, low-weight pressure vessel dome was designed specifically to house a high-pressure [2,000 psi (approx. = 13.8 MPa)] electrolyzer. In operation, the dome is filled with an inert gas pressurized to roughly 100 psi (approx. = 690 kPa) above the high, balanced pressure product oxygen and hydrogen gas streams. The inert gas acts to reduce the clamping load on electrolyzer stack tie bolts since the dome pressure acting axially inward helps offset the outward axial forces from the stack gas pressure. Likewise, radial and circumferential stresses on electrolyzer frames are minimized. Because the dome is operated at a higher pressure than the electrolyzer product gas, any external electrolyzer leak prevents oxygen or hydrogen from leaking into the dome. Instead the affected stack gas stream pressure rises detectably, thereby enabling a system shutdown. All electrical and fluid connections to the stack are made inside the pressure dome and require special plumbing and electrical dome interfaces for this to be accomplished. Further benefits of the dome are that it can act as a containment shield in the unlikely event of a catastrophic failure. Studies indicate that, for a given active area (and hence, cell ID), frame outside diameter must become ever larger to support stresses at higher operating pressures. This can lead to a large footprint and increased costs associated with thicker and/or larger diameter end-plates, tie-rods, and the frames themselves. One solution is to employ rings that fit snugly around the frame. This complicates stack assembly and is sometimes difficult to achieve in practice, as its success is strongly dependent on frame and ring tolerances, gas pressure, and operating temperature. A pressure dome permits an otherwise low-pressure stack to operate at higher pressures without growing the electrolyzer hardware. The pressure dome consists of two machined segments. An O-ring is placed in an O-ring groove in the flange of the bottom segment and is trapped by the flange on the top dome segment when these components are bolted together with high-strength bolts. The pressure dome has several unique features. It is made (to ASME Pressure Vessel guidelines) in a high-strength aluminum alloy with the strength of stainless steel and the weight benefits of aluminum. The flange of the upper dome portion contains specially machined flats for mounting the dome, and other flats dedicated to the special feedthroughs for electrical connections. A pressure dome can be increased in length to house larger stacks (more cells) of the same diameter with the simple addition of a cylindrical segment. To aid in dome assembly, two stainless steel rings are employed. One is used beneath the heads of the high-strength bolts in lieu of individual hardened washers, and another is used instead of individual nuts. Like electrolyzers could be operated at low or high pressures simply by operating the electrolyzer outside or inside a pressurized dome.

Norman, Timothy↗
NASA NTRS2012

Sapphire Viewports for a Venus Probe

A document discusses the creation of a viewport suitable for use on the surface of Venus. These viewports are rated for 500 C and 100 atm pressure with appropriate safety factors and reliability required for incorporation into a Venus Lander. Sapphire windows should easily withstand the chemical, pressure, and temperatures of the Venus surface. Novel fixture designs and seals appropriate to the environment are incorporated, as are materials compatible with exploration vessels. A test cell was fabricated, tested, and leak rate measured. The window features polish specification of the sides and corners, soft metal padding of the sapphire, and a metal C-ring seal. The system safety factor is greater than 2, and standard mechanical design theory was used to size the window, flange, and attachment bolts using available material property data. Maintenance involves simple cleaning of the window aperture surfaces. The only weakness of the system is its moderate rather than low leak rate for vacuum applications.

Bates, Stephen↗
NASA NTRS2013

High-Reliability Waveguide Vacuum/Pressure Window

The NASA Deep Space Network (DSN) uses commercial waveguide windows on the output waveguide of Ka-band (32 GHz) low-noise amplifiers. Mechanical failure of these windows resulted in an unacceptable loss in tracking time. To address this issue, a new Ka-band WR-28 waveguide window has been designed, fabricated, and tested. The window uses a slab of low-loss, low-dielectric constant foam that is bonded into a 1/2-wave-thick waveguide/flange. The foam is a commercially available, rigid, closed-cell polymethacrylimide. It has excellent electrical properties with a dielectric constant of 1.04, and a loss tangent of 0.01. It is relatively strong with a tensile strength of 1 MPa. The material is virtually impermeable to helium. The finished window exhibits a leak rate of less than 3x10(exp -3)cu cm/s with helium. The material is also chemically resistant and can be cleaned with acetone. The window is constructed by fabricating a window body by brazing a short length of WR-28 copper waveguide into a standard rectangular flange, and machining the resulting part to a thickness of 4.6 mm. The foam is machined to a rectangular shape with a dimension of 7.06x3.53 mm. The foam is bonded into the body with a two-part epoxy. After curing, the excess glue and foam are knife-trimmed by hand. The finished window has a loss of less than 0.08 dB (2%) and a return loss of greater than 25 dB at 32 GHz. This meets the requirements for the DSN application. The window is usable for most applications over the entire 26-to-40-GHz waveguide band. The window return loss can be tuned to a required frequency by var y in g the thickness of the window slightly. Most standard waveguide windows use a thin membrane of material bonded into a recess in a waveguide flange, or sandwiched between two flanges with a polymer seal. Designs using the recessed window are prone to mechanical failure over time due to constraints on the dimensions of the recess that allow the bond to fail. Designs using the sandwich method are often permeable to helium, which prohibits the use of helium leak detection. At the time of this reporting, 40 windows have been produced. Twelve are in operation with a combined operating time of over 30,000 hours without a failure.

Britcliffe, Michael J.↗
NASA NTRS2007

Effect of PdO on TiO(sub2) Loading on Chemochromic Detection of Hydrogen

Safety is always a concern in all applications that utilize hydrogen (H(sub2)) in one form or the other. Hydrogen leaks are invisible and odorless. In addition, blending odorants or additives into hydrogen in a manner similar to natural gas is generally undesirable for certain applications including proton exchange membrane fuel cells. To facilitate detection of the location of hydrogen leaks, a special chemochromic H(sub2) sensing material that employs titania (Ti0(sub2)) supported palladium oxide (PdO) pigments encapsulated within a special silicone matrix has been developed at the Florida Solar Energy Center (FSEC). Several batches of PdO H(sub2) sensing pigments were synthesized using various Ti0(sub2) supports and their hydrogen detection activity determined. TEM and Particle size distribution analysis showed that smaller particles with hemispherical crystalline structure produced faster coloration kinetics when exposed to H(sub2) gas. However, uniformly distributed PdO particles on the Ti0(sub2) surface displayed greater color contrast, quantified by delta epsilon measurements. XRD analysis indicated that the crystalline phase of Ti0(sub2) had no effect on the chemochromic performance of the pigments in laboratory environment.

Mohajeri, Nahid↗
NASA NTRS2013

Hermetic Seal Designs for Sample Return Sample Tubes

Prototypes have been developed of potential hermetic sample sealing techniques for encapsulating samples in a ≈1-cm-diameter thin-walled sample tube that are compatible with IMSAH (Integrated Mars Sample Acquisition and Handling) architecture. Techniques include a heat-activated, finned, shape memory alloy plug; a contracting shape memory alloy activated cap; an expanding shape memory alloy plug; and an expanding torque plug. Initial helium leak testing of the shape memory alloy cap and finned shape memory alloy plug seals showed hermetic- seal capability compared against an industry standard of <1×10-8 atm-cc/s He. These tests were run on both clean tubes and dirty tubes dipped in MMS (Mojave Mars Simulant). The leak tests were also performed after thermal cycling between -135 and +55 ºC to ensure seal integrity after Martian diurnal cycles. Developmental testing is currently being done on the expanding torque plug, and expanding shape memory alloy plug seal designs. The finned shape memory alloy (SMA) plug currently shows hermetic sealing capability based on preliminary tests.

Younse, Paulo J.↗
NASA NTRS2014

Calibration of International Space Station (ISS) Node 1 Vibro-Acoustic Model

Reported here is the ability of utilizing the Energy Finite Element Method (E-FEM) to predict the vibro-acoustic sound fields within the International Space Station (ISS) Node 1 and to compare the results with actual measurements of leak sounds made by a one atmosphere to vacuum leak through a small hole in the pressure wall of the Node 1 STA module during its period of storage at Stennis Space Center (SSC). While the E-FEM method represents a reverberant sound field calculation, of importance to this application is the requirement to also handle the direct field effect of the sound generation. It was also important to be able to compute the sound fields in the ultrasonic frequency range. This report demonstrates the capability of this technology as applied to this type of application.

Zhang, Weiguo↗
NASA NTRS2014

Calibration of International Space Station (ISS) Node 1 Vibro-Acoustic Model-Report 2

Reported here is the capability of the Energy Finite Element Method (E-FEM) to predict the vibro-acoustic sound fields within the International Space Station (ISS) Node 1 and to compare the results with simulated leak sounds. A series of electronically generated structural ultrasonic noise sources were created in the pressure wall to emulate leak signals at different locations of the Node 1 STA module during its period of storage at Stennis Space Center (SSC). The exact sound source profiles created within the pressure wall at the source were unknown, but were estimated from the closest sensor measurement. The E-FEM method represents a reverberant sound field calculation, and of importance to this application is the requirement to correctly handle the direct field effect of the sound generation. It was also important to be able to compute the sound energy fields in the ultrasonic frequency range. This report demonstrates the capability of this technology as applied to this type of application.

Zhang, Weiguo↗
NASA NTRS2014

Familiarization and Detection of Green Monopropellants Project

Ammonium dinitramide (ADN) and hydroxyl ammonium nitrate (HAN) are green monopropellants which will be appearing at Kennedy Space Center (KSC) for processing in the next few years. These are relatively safe replacements for hydrazine as a monopropellant; however, little is known about methods of leak detection, vapor scrubbing, air emissions, or cleanup that will be required for safe and environmentally benign operations at KSC. The goal of this work is to develop leak detection and related technologies for the two new green monopropellants.

Technology Portfolio System↗
NASA NTRS2013

NASA Spinoff Article: Automated Procedures To Improve Safety on Oil Rigs

On May 11th, 2013, two astronauts emerged from the interior of the International Space Station (ISS) and worked their way toward the far end of spacecraft. Over the next 51/2 hours, the two replaced an ammonia pump that had developed a significant leak a few days before. On the ISS, ammonia serves the vital role of cooling components-in this case, one of the station's eight solar arrays. Throughout the extravehicular activity (EVA), the astronauts stayed in constant contact with mission control: every movement, every action strictly followed a carefully planned set of procedures to maximize crew safety and the chances of success. Though the leak had come as a surprise, NASA was prepared to handle it swiftly thanks in part to the thousands of procedures that have been written to cover every aspect of the ISS's operations. The ISS is not unique in this regard: Every NASA mission requires well-written procedures-or detailed lists of step-by-step instructions-that cover how to operate equipment in any scenario, from normal operations to the challenges created by malfunctioning hardware or software. Astronauts and mission control train and drill extensively in procedures to ensure they know what the proper procedures are and when they should be used. These procedures used to be exclusively written on paper, but over the past decade, NASA has transitioned to digital formats. Electronic-based documentation simplifies storage and use, allowing astronauts and flight controllers to find instructions more quickly and display them through a variety of media. Electronic procedures are also a crucial step toward automation: once instructions are digital, procedure display software can be designed to assist in authoring, reviewing, and even executing them.

traclabs↗
NASA NTRS2014

Green Applications for Space Power Project

Spacecraft propulsion and power for many decades has relied on Hydrazine monopropellant technology for auxiliary power units (APU), orbital circularization, orbit raising/lowering and attitude control. However, Hydrazine is toxic and therefore requires special ground handling procedures to ensure launch crew safety. The Swedish Company ECAPS has developed a technology based upon the propellant Ammonium Dinitramide (ADN) that offers higher performance, higher density and reduced ground handling support than Hydrazine. This blended propellant is called LMP-103S. Currently, the United States Air Force (USAF) is pursuing a technology based on Hydroxyl Ammonium Nitrate (HAN, otherwise known as AF-M315E) with industry partners Aerojet and Moog. Based on the advantages offered by these propellants, MSFC should explore powering APU's with these propellants. Due to the availability of space hardware, the principal investigator has found a collection of USAF hardware, that will act as a surrogate, which operates on a Hydrazine derivative. The F-16 fighter jet uses H-70 or 30% diluted Hydrazine for an Emergency Power Unit (EPU) which supplies power to the plane. The PI has acquired two EPU's from planes slated for destruction at the Davis Monthan AFB. This CIF will include a partnership with 2 other NASA Centers who are individually seeking seed funds from their respective organizations: Kennedy Space Center (KSC) and Dryden Flight Research Center (DFRC). KSC is preparing for future flights from their launch pads that will utilize green propellants and desire a low-cost testbed in which to test and calibrate new leak detection sensors. DFRC has access to F-16's which can be used by MSFC & KSC to perform a ground test that demonstrates emergency power supplied to the jet. Neither of the green propellant alternatives have been considered nor evaluated for an APU application. Work has already been accomplished to characterize and obtain the properties of these 2 propellants. However, the spacecraft are using existing leak detection sensors that are typically used for Hydrazine. Using these green propellants for the APU application requires decrementing their TRL down to 3. This task would aim to establish a TRL of 4 at conclusion by showing a proof of concept with a KSC-instrumented EPU asset at the MSFC Component Development Area (CDA). The task to accomplish this is called Green Application for Space Power or GRASP.

Robinson, Joel↗
NASA NTRS2014

An Overview of Advanced Elastomeric Seal Development and Testing Capabilities at NASA Glenn Research Center

NASA is developing advanced space-rated elastomeric seals to support future space exploration missions to low Earth orbit, the Moon, near Earth asteroids, and other destinations. This includes seals for a new docking system and vehicle hatches. These seals must exhibit extremely low leak rates to ensure that astronauts have sufficient breathable air for extended missions. Seal compression loads must be below prescribed limits so as not to overload the mechanisms that compress them, and seal adhesion forces must be low to allow the sealed interface to be separated when required (e.g., during undocking or hatch opening). NASA Glenn Research Center has developed a number of unique test fixtures to measure the leak rates and compression and adhesion loads of candidate seal designs under simulated thermal, vacuum, and engagement conditions. Tests can be performed on fullscale seals with diameters on the order of 50 in., subscale seals that are about 12 in. in diameter, and smaller specimens such as O-rings. Test conditions include temperatures ranging from -238 to 662degF (-150 to 350degC), operational pressure gradients, and seal-on-seal or seal-on-flange mating configurations. Nominal and off-nominal conditions (e.g., incomplete seal compression) can also be simulated. This paper describes the main design features and capabilities of each type of test apparatus and provides an overview of advanced seal development activities at NASA Glenn.

Leakage↗
NASA NTRS2014

An Overview of Advanced Elastomeric Seal Development and Testing Capabilities at NASA Glenn Research Center

NASA is developing advanced space-rated elastomeric seals to support future space exploration missions to low Earth orbit, the Moon, near Earth asteroids, and other destinations. This includes seals for a new docking system and vehicle hatches. These seals must exhibit extremely low leak rates to ensure that astronauts have sufficient breathable air for extended missions. Seal compression loads must be below prescribed limits so as not to overload the mechanisms that compress them, and seal adhesion forces must be low to allow the sealed interface to be separated when required (e.g., during undocking or hatch opening). NASA Glenn Research Center has developed a number of unique test fixtures to measure the leak rates and compression and adhesion loads of candidate seal designs under simulated thermal, vacuum, and engagement conditions. Tests can be performed on full-scale seals with diameters on the order of 50 in., subscale seals that are about 12 in. in diameter, and smaller specimens such as O-rings. Test conditions include temperatures ranging from -238 to +662F (-150 to +350C), operational pressure gradients, and seal-on-seal or seal-on-flange mating configurations. Nominal and off-nominal conditions (e.g., incomplete seal compression) can also be simulated. This paper describes the main design features and capabilities of each test apparatus and provides an overview of advanced seal development activities at NASA Glenn.

Leakage↗
NASA NTRS2014

An Overview of Advanced Elastomeric Seal Development and Testing Capabilities at NASA Glenn Research Center

NASA is developing advanced space-rated elastomeric seals to support future space exploration missions to low Earth orbit, the Moon, near Earth asteroids, and other destinations. This includes seals for a new docking system and vehicle hatches. These seals must exhibit extremely low leak rates to ensure that astronauts have sufficient breathable air for extended missions. Seal compression loads must be below prescribed limits so as not to overload the mechanisms that compress them, and seal adhesion forces must be low to allow the sealed interface to be separated when required (e.g., during undocking or hatch opening). NASA Glenn Research Center has developed a number of unique test fixtures to measure the leak rates and compression and adhesion loads of candidate seal designs under simulated thermal, vacuum, and engagement conditions. Tests can be performed on full-scale seals with diameters on the order of 50 in., subscale seals that are about 12 in. in diameter, and smaller specimens such as O-rings. Test conditions include temperatures ranging from -238 to 662 F (-150 to 350 C), operational pressure gradients, and seal-on-seal or seal-on-flange mating configurations. Nominal and off-nominal conditions (e.g., incomplete seal compression) can also be simulated. This paper describes the main design features and capabilities of each type of test apparatus and provides an overview of advanced seal development activities at NASA Glenn.

Compression tests↗