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Cryogenic thermal control technology summaries

A summarization and categorization is presented of the pertinent literature associated with cryogenic thermal control technology having potential application to in-orbit fluid transfer systems and/or associated space storage. Initially, a literature search was conducted to obtain pertinent documents for review. Reports determined to be of primary significance were summarized in detail. Each summary, where applicable, consists of; (1) report identification, (2) objective(s) of the work, (3) description of pertinent work performed, (4)major results, and (5) comments of the reviewer (GD/C). Specific areas covered are; (1) multilayer insulation of storage tanks with and without vacuum jacketing, (2) other insulation such as foams, shadow shields, microspheres, honeycomb, vent cooling and composites, (3) vacuum jacketed and composite fluid lines, and (4) low conductive tank supports and insulation penetrations. Reports which were reviewed and not summarized, along with reasons for not summarizing, are also listed.

Stark, J. A.↗

Resistively-Heated Microlith-based Adsorber for Carbon Dioxide and Trace Contaminant Removal

An integrated sorber-based Trace Contaminant Control System (TCCS) and Carbon Dioxide Removal Assembly (CDRA) prototype was designed, fabricated and tested. It corresponds to a 7-person load. Performance over several adsorption/regeneration cycles was examined. Vacuum regenerations at effective time/temperature conditions, and estimated power requirements were experimentally verified for the combined CO2/trace contaminant removal prototype. The current paper details the design and performance of this prototype during initial testing at CO2 and trace contaminant concentrations in the existing CDRA, downstream of the drier. Additional long-term performance characterization is planned at NASA. Potential system design options permitting associated weight, volume savings and logistic benefits, especially as relevant for long-duration space flight, are reviewed. The technology consisted of a sorption bed with sorbent- coated metal meshes, trademarked and patented as Microlith by Precision Combustion, Inc. (PCI). By contrast the current CO2 removal system on the International Space Station employs pellet beds. Preliminary bench scale performance data (without direct resistive heating) for simultaneous CO2 and trace contaminant removal was reviewed in SAE 2004-01-2442. In the prototype, the meshes were directly electrically heated for rapid response and accurate temperature control. This allowed regeneration via resistive heating with the potential for shorter regeneration times, reduced power requirement, and net energy savings vs. conventional systems. A novel flow arrangement, for removing both CO2 and trace contaminants within the same bed, was demonstrated. Thus, the need for a separate trace contaminant unit was eliminated resulting in an opportunity for significant weight savings. Unlike the current disposable charcoal bed, zeolites for trace contaminant removal are amenable to periodic regeneration.

Roychoudhury, S.↗

Development of a Test Facility for Air Revitalization Technology Evaluation

Development of new air revitalization system (ARS) technology can initially be performed in a subscale laboratory environment, but in order to advance the maturity level, the technology must be tested in an end-to-end integrated environment. The Air Revitalization Technology Evaluation Facility (ARTEF) at the NASA Johnson Space Center serves as a ground test bed for evaluating emerging ARS technologies in an environment representative of spacecraft atmospheres. At the center of the ARTEF is a hypobaric chamber which serves as a sealed atmospheric chamber for closed loop testing. A Human Metabolic Simulator (HMS) was custom-built to simulate the consumption of oxygen, and production of carbon dioxide, moisture and heat of up to eight persons. A multitude of gas analyzers and dew point sensors are used to monitor the chamber atmosphere upstream and downstream of a test article. A robust vacuum system is needed to simulate the vacuum of space. A reliable data acquisition and control system is required to connect all the subsystems together. This paper presents the capabilities of the integrated test facility and some of the issues encountered during the integration.

Lu, Sao-Dung↗

Reflecting on Space Benefits: A Shining Example

NASA has long been known for having developed the thin, shiny reflective material used to insulate everything from the Hubble Space Telescope to hikers, from the Mars rovers to marathon runners, from computers to campers, from satellites to sun shields, and from rockets to residences. It is one of the simplest, yet most versatile spinoffs to come out of the Agency. The insulating material, a strong, plastic, vacuum-metallized film with a highly-efficient, infrared-reflective, vapor-deposited coating of aluminum, was created to be very lightweight in order to minimize weight impact on vehicle payload while also protecting spacecraft, equipment, and personnel from the extreme temperature fluctuations of space. It has been employed on virtually all manned and unmanned NASA missions. The shiny insulation which coated the base of the Apollo lunar landing vehicles is perhaps one of the most memorable early displays of this technology, and the bright, reflective honeycomb on the James Webb Space Telescope prototype is a testament to its lasting usefulness.

Source record↗

Cleaning Process Development for Metallic Additively Manufactured Parts

Additive Manufacturing of metallic components for aerospace applications offers many advantages over traditional manufacturing techniques. As a new technology, many aspects of its widespread utilization remain open to investigation. Among these are the cleaning processes that can be used for post finishing of parts and measurements to verify effectiveness of the cleaning processes. Many cleaning and drying processes and measurement methods that have been used for parts manufactured using conventional techniques are candidates that may be considered for cleaning and verification of additively manufactured parts. Among these are vapor degreasing, ultrasonic immersion and spray cleaning, followed by hot air drying, vacuum baking and solvent displacement drying. Differences in porosity, density, and surface finish of additively manufactured versus conventionally manufactured parts may introduce new considerations in the selection of cleaning and drying processes or the method used to verify their effectiveness. This presentation will review the relative strengths and weaknesses of different candidate cleaning and drying processes as they may apply to additively manufactured metal parts for aerospace applications. An ultrasonic cleaning technique for exploring the cleanability of parts will be presented along with an example using additively manufactured Inconel 718 test specimens to illustrate its use. The data analysis shows that this ultrasonic cleaning approach results in a well-behaved ultrasonic cleaning/extraction behavior. That is, it does not show signs of accelerated cavitation erosion of the base material, which was later confirmed by neutron imaging. In addition, the analysis indicated that complete cleaning would be achieved by ultrasonic immersion cleaning at approximately 5 minutes, which was verified by subsequent cleaning of additional parts.

Tramel, Terri L.↗

Enzyme-based CO2 capture for advanced life support

Elevated CO2 levels in air can lead to impaired functioning and even death to humans. Control of CO2 is critical in confined spaces that have little physical or biological buffering capacity (e.g., spacecraft, submarines, or aircraft). A novel enzyme-based contained liquid membrane bioreactor was designed for CO2 capture and certain application cases are reported in this article. The results show that the liquid layer accounts for the major transport resistance. With addition of carbonic anhydrase, the transport resistance decreased by 71%. Volatile organic compounds of the type and concentration expected to be present in either the crew cabin or a plant growth chamber did not influence carbonic anhydrase activity or reactor operation during 1-day operation. Alternative sweep method studies, examined as a means of eliminating consumables, showed that the feed gas could be used successfully in a bypass mode when combined with medium vacuum pressure (-85 kPa) to achieve CO2 separation comparable to that with an inert sweep gas. The reactor exhibited a selectivity for CO2 versus N2 of 1400:1 and CO2 versus O2 is 866:1. The CO2 permeance was 1.44 x 10(-7) mol m-2 Pa-1 s-1 (4.3 x 10(-4) cm3 cm-2 s-1 cmHg-1) at a feed concentration of 0.1% CO2. These data show that the enzyme-based contained liquid membrane is a promising candidate technology that may be suitable for NASA applications to control CO2 in the crew or plant chambers.

NASA Discipline Life Support Systems↗

2009 Continued Testing of the Orion Atmosphere Revitalization Technology

An amine-based carbon dioxide (CO2) and water vapor sorbent in pressure-swing regenerable beds has been developed by Hamilton Sundstrand and baselined for the Orion Atmosphere Revitalization System (ARS). In three previous years at this conference, reports were presented on extensive Johnson Space Center (JSC) testing of this technology in a sea-level pressure environment with simulated and real human metabolic loads in both open and closed-loop configurations. The test article design was iterated a third time before the latest series of such tests, which was performed in the first half of 2009. The new design incorporates a canister configuration modification for overall unit compactness and reduced pressure drop, as well as a new process flow control valve that incorporates both compressed gas purge and dual-end vacuum desorption capabilities. This newest test article is very similar to the flight article designs. Baseline tests of the new unit were performed to compare its performance to that of the previous test articles. Testing of compressed gas purge operations helped refine launchpad operating condition recommendations developed in earlier testing. Operating conditions used in flight program computer models were tested to validate the model projections. Specific operating conditions that were recommended by the JSC test team based on past test results were also tested for validation. The effects of vacuum regeneration line pressure on resulting cabin conditions was studied for high metabolic load periods, and a maximum pressure is recommended.

Button, Amy Lin↗

2009 Continued Testing of the Orion Atmosphere Revitalization Technology

An amine-based carbon dioxide (CO2) and water vapor sorbent in pressure-swing regenerable beds has been developed by Hamilton Sundstrand and baselined for the Orion Atmosphere Revitalization System (ARS). In three previous years at this conference, reports were presented on extensive Johnson Space Center (JSC) testing of this technology in a sea-level pressure environment, with simulated and real human metabolic loads, in both open and closed-loop configurations. The test article design was iterated a third time before the latest series of such tests, which was performed in the first half of 2009. The new design incorporates a canister configuration modification for overall unit compactness and reduced pressure drop, as well as a new process flow control valve that incorporates both compressed gas purge and dual-end vacuum desorption capabilities. This newest test article is very similar to the flight article designs. Baseline tests of the new unit were performed to compare its performance to that of the previous test articles. Testing of compressed gas purge operations helped refine launchpad operating condition recommendations developed in earlier testing. Operating conditions used in flight program computer models were tested to validate the model projections. Specific operating conditions that were recommended by the JSC test team based on past test results were also tested for validation. The effects of vacuum regeneration line pressure on resulting cabin conditions was studied for high metabolic load periods, and a maximum pressure is recommended

Button, Amy B.↗

Cascade Distillation Subsystem Development: Progress Toward a Distillation Comparison Test

Recovery of potable water from wastewater is essential for the success of long-duration manned missions to the Moon and Mars. Honeywell International and a team from NASA Johnson Space Center (JSC) are developing a wastewater processing subsystem that is based on centrifugal vacuum distillation. The wastewater processor, referred to as the Cascade Distillation Subsystem (CDS), utilizes an innovative and efficient multistage thermodynamic process to produce purified water. The rotary centrifugal design of the system also provides gas/liquid phase separation and liquid transport under microgravity conditions. A five-stage subsystem unit has been designed, built, delivered and integrated into the NASA JSC Advanced Water Recovery Systems Development Facility for performance testing. A major test objective of the project is to demonstrate the advancement of the CDS technology from the breadboard level to a subsystem level unit. An initial round of CDS performance testing was completed in fiscal year (FY) 2008. Based on FY08 testing, the system is now in development to support an Exploration Life Support (ELS) Project distillation comparison test expected to begin in early 2009. As part of the project objectives planned for FY09, the system will be reconfigured to support the ELS comparison test. The CDS will then be challenged with a series of human-gene-rated waste streams representative of those anticipated for a lunar outpost. This paper provides a description of the CDS technology, a status of the current project activities, and data on the system s performance to date.

Callahan, M. R.↗

Laboratory Demonstration of High Contrast with the PIAACMC Coronagraph on an Obstructed and Segmented Aperture

Coronagraphs (together with starshades) are an important tool to directly image and characterize exoplanets, and enable the search for biomarkers in reflected light on potentially habitable worlds. Their performance and efficiency has steadily been improving over the past several decades, but has not yet reached performance limits. In particular, the expected exoplanet yield for missions such as the Astro2020-recommended “IR/O/UV Flagship” can still be improved by factors of at least 2-3, simply by continued improvements in coronagraph performance, before they plateau due to physics limits. One possible architecture that can enable at least a part of this improvement is the Phase-Induced Amplitude Apodization Complex Mask Coronagraph (PIAACMC). Itoffersthe advantages of high throughput, small inner working angle (IWA),and almost noloss inPSF sharpness, and natively supports obstructed and segmented apertures, which is essential to the Astro2020 “IR/O/UV Flagship”mission. Historically, key disadvantages of PIAA have been poor tolerance to stellar angular sizes and maturity, but latest designs and demonstrations have made significant strides in this respect.In this paper, we present the current status and overview of our program to mature the PIAACMC technology. We first review PIAACMC designs for LUVOIR-A and B, which resultedin improved expected yield of Exo-Earths relative tothe baselines for both mission concepts. In particular, for LUVOIR-B, the yield improves from 28 to 42due to improvedtolerance to stellar angular size in our design. The improvement in yield is marginal for LUVOIR-A, but our design enables detecting planets around smaller diameter stars (nearby K-dwarfs and/or farther FG stars). We also describe our modeling and vacuum demonstrationsfor the LUVOIR-A aperture(which is more challengingthan LUVOIR-B due to the central obstruction).The demonstration included a LUVOUR-A pupil mask, an on-axis PIAA set of 2 mirrors with central holes, a Boston Micromachines DM, a patterned CMC mask, Lyot stop, and supporting masks and optics. Demonstrations were conducted at JPL’s High Contrast Imaging Testbed (HCIT) using several characterization andwavefront control techniques (primarily standard EFC, several experimental techniques were attempted, as well as speckle nulling). So far, our results include 1.9e-8 raw contrast in 10% broadband light between 3.5 and 8 l/D; 4.1e-8 and 1.6e-9 coherent contrasts in monochromatic light between 2-4 and 4-8 l/D, respectively. We also present measurements and analysis of sensitivity to tip/tilt jitter and stellar angular size. Finally, we compare our test results to models, present an analysis of our limiting factors, and explorefuture prospectsfor improvement based on validated models.

Coronagraph↗

QS ATMS Calibration Data Book Government Version: Pre-Launch Version

The Advanced Technology Microwave Sounder (ATMS) SN301 is an instrument onboard the QuickSounder Satellite System, QuickSounder mission (renamed QS). Throughout this document the mission may be referred to as QuickSounder or QS. The purpose of this document is to provide information needed to interpret and process QS ATMS science data. The contents of the data book incorporate results from pre-launch subsystem-level and instrument-level testing as well as post-launch testing performed during instrument commissioning. Major milestones include instrument thermal vacuum (TVAC) testing in May 2024 and observatory TVAC testing in 2026. QS launch will be no earlier than Feb. 15, 2027.

Microwave Radiometer↗

Evaluation of a Multi-kw, High Frequency Transformer for Space Applications

Various NASA studies have shown that high power (multi-kW and higher) electrical systems for various aerospace applications favor high frequency distribution systems, due to the improved safety and weight factors associated with those systems. Other favorable characteristics include low EMI, minimal wiring and ease of system parameter sensing and control of a single phase system. In aerospace power systems, as in terrestrial AC distribution systems, transformers are needed to provide voltage changes, isolation and the resetting of ground. Under NASA contract NAS3-21948 a multi-kW high frequency transformer was designed, fabricated and tested by Thermal Technology Lab, Inc. of Buffalo, New York. 'The goals of this program included the determination of the relationships between transformer weight, efficiency and operating frequency; low internal temperatures and reduced specific weight; and the validation of these new design concepts through experimentation and the fabrication and testing of transformers and their insulation systems.' The transformer was delivered to NASA-Lewis, where an evaluation program was conducted in Lewis' High Power High Frequency Component Test Facility. The transformer was tested in both atmosphere and under vacuum conditions. This paper will discuss the design of the transformer, the evaluation program and test results, the failures experienced and conclusions.

Roth, Mary Ellen↗

Development and Testing of a Sorbent-Based Atmosphere Revitalization System 2010/2011

Spacecraft being developed for future exploration missions incorporate Environmental Control and Life Support Systems (ECLSS) that limit weight, power, and volume thus requiring systems with higher levels of efficiency while maintaining high dependability and robustness. For air revitalization, an approach that meets those goals utilizes a regenerative Vacuum-Swing Adsorption (VSA) system that removes 100% of the CO2 from the cabin atmosphere as well as 100% of the water. A Sorbent Based Atmosphere Revitalization (SBAR) system is a VSA system that utilizes standard commercial adsorbents that have been proven effective and safe in spacecraft including Skylab and the International Space Station. The SBAR system is the subject of a development, test, and evaluation program that is being conducted at NASA s Marshall Space Flight Center. While previous testing had validated that the technology is a viable option, potential improvements to system design and operation were identified. Modifications of the full-scale SBAR test articles and adsorption cycles have been implemented and have shown significant performance gains resulting in a decrease in the consumables required for a mission as well as improved mission safety. Previous testing had utilized single bed test articles, during this period the test facility was enhanced to allow testing on the full 2-bed SBAR system. The test facility simulates a spacecraft ECLSS and allows testing of the SBAR system over the full range of operational conditions using mission simulations that assess the real-time performance of the SBAR system during scenarios that include the metabolic transients associated with extravehicular activity. Although future manned missions are currently being redefined, the atmosphere revitalization requirements for the spacecraft are expected to be quite similar to the Orion and the Altair vehicles and the SBAR test program addressed validation to the defined mission requirements as well as operation in other potential vehicle architectures. The development program, including test articles, the test facility, and tests and results through early 2011 is discussed.

Miller, Lee A.↗

Development of high resolution imaging detectors for x ray astronomy

This final report summarizes our past activities and discusses the work performed over the period of 1 April 1990 through 1 April 1991 on x-ray optics, soft x-ray (0.1 - 10 KeV) imaging detectors, and hard x-ray (10 - 300 KeV) imaging detectors. If microchannel plates (MCPs) can be used to focus x-rays with a high efficiency and good angular resolution, they will revolutionize the field of x-ray optics. An x-ray image of a point source through an array of square MCP pores compared favorably with our ray tracing model for the MCP. Initial analysis of this image demonstrates the feasibility of MCPs for soft x-rays. Our work continues with optimizing the performance of our soft x-ray MCP imaging detectors. This work involves readout technology that should provide improved MCP readout devices (thin film crossed grid, curved, and resistive sheets), defect removal in MCPs, and photocathode optimization. In the area of hard x-ray detector development we have developed two different techniques for producing a CsI photocathode thickness of 10 to 100 microns, such that it is thick enough to absorb the high energy x-rays and still allow the photoelectrons to escape to the top MCP of a modified soft x-ray imaging detector. The methods involve vacuum depositing a thick film of CsI on a strong back, and producing a converter device that takes the place of the photocathode.

Murray, S. S.↗

Comparison of Classical and Charge Storage Methods for Determining Conductivity of Thin Film Insulators

Conductivity of insulating materials is a key parameter to determine how accumulated charge will distribute across the spacecraft and how rapidly charge imbalance will dissipate. Classical ASTM and IEC methods to measure thin film insulator conductivity apply a constant voltage to two electrodes around the sample and measure the resulting current for tens of minutes. However, conductivity is more appropriately measured for spacecraft charging applications as the "decay" of charge deposited on the surface of an insulator. Charge decay methods expose one side of the insulator in vacuum to sequences of charged particles, light, and plasma, with a metal electrode attached to the other side of the insulator. Data are obtained by capacitive coupling to measure both the resulting voltage on the open surface and emission of electrons from the exposed surface, as well monitoring currents to the electrode. Instrumentation for both classical and charge storage decay methods has been developed and tested at Jet Propulsion Laboratory (JPL) and at Utah State University (USU). Details of the apparatus, test methods and data analysis are given here. The JPL charge storage decay chamber is a first-generation instrument, designed to make detailed measurements on only three to five samples at a time. Because samples must typically be tested for over a month, a second-generation high sample throughput charge storage decay chamber was developed at USU with the capability of testing up to 32 samples simultaneously. Details are provided about the instrumentation to measure surface charge and current; for charge deposition apparatus and control; the sample holders to properly isolate the mounted samples; the sample carousel to rotate samples into place; the control of the sample environment including sample vacuum, ambient gas, and sample temperature; and the computer control and data acquisition systems. Measurements are compared here for a number of thin film insulators using both methods at both facilities. We have found that conductivity determined from charge storage decay methods is 102 to 104 larger than values obtained from classical methods. Another Spacecraft Charging Conference presentation describes more extensive measurements made with these apparatus. This work is supported through funding from the NASA Space Environments and Effects Program and the USU Space Dynamics Laboratory Enabling Technologies Program.

Swaminathan, Prasanna↗

Multi-Scale CNT-Based Reinforcing Polymer Matrix Composites for Lightweight Structures

Reinforcing critical areas in carbon polymer matrix composites (PMCs), also known as fiber reinforced composites (FRCs), is advantageous for structural durability. Since carbon nanotubes (CNTs) have extremely high tensile strength, they can be used as a functional additive to enhance the mechanical properties of FRCs. However, CNTs are not readily dispersible in the polymer matrix, which leads to lower than theoretically predicted improvement in mechanical, thermal, and electrical properties of CNT composites. The inability to align CNTs in a polymer matrix is also a known issue. The feasibility of incorporating aligned CNTs into an FRC was demonstrated using a novel, yet commercially viable nanofiber approach, termed NRMs (nanofiber-reinforcing mats). The NRM concept of reinforcement allows for a convenient and safe means of incorporating CNTs into FRC structural components specifically where they are needed during the fabrication process. NRMs, fabricated through a novel and scalable process, were incorporated into FRC test panels using layup and vacuum bagging techniques, where alternating layers of the NRM and carbon prepreg were used to form the reinforced FRC structure. Control FRC test panel coupons were also fabricated in the same manner, but comprised of only carbon prepreg. The FRC coupons were machined to size and tested for flexural, tensile, and compression properties. This effort demonstrated that FRC structures can be fabricated using the NRM concept, with an increased average load at break during flexural testing versus that of the control. The NASA applications for the developed technologies are for lightweight structures for in-space and launch vehicles. In addition, the developed technologies would find use in NASA aerospace applications such as rockets, aircraft, aircraft/spacecraft propulsion systems, and supporting facilities. The reinforcing aspect of the technology will allow for more efficient joining of fiber composite parts, thus offering additional weight savings. More robust structures capable of withstanding micrometeoroid and space debris impacts will be possible with the enhanced mechanical properties imparted by the aligned CNTs incorporated into the fiber composite structure, as well as the potential for improved electrical and thermal properties. The materials fabrication approach developed in the present effort is a platform for customer applications where additional reinforcement is required or would be beneficial, especially in FRC structures and component parts. Depending upon the specific customer application, the NRM could be tailored to the specific matrix resin and desired property enhancement.

Eberly, Daniel↗

Hollow-Fiber Spacesuit Water Membrane Evaporator

The hollow-fiber spacesuit water membrane evaporator (HoFi SWME) is being developed to perform the thermal control function for advanced spacesuits and spacecraft to take advantage of recent advances in micropore membrane technology in providing a robust, heat-rejection device that is less sensitive to contamination than is the sublimator. After recent contamination tests, a commercial-off-the-shelf (COTS) micro porous hollow-fiber membrane was selected for prototype development as the most suitable candidate among commercial hollow-fiber evaporator alternatives. An innovative design that grouped the fiber layers into stacks, which were separated by small spaces and packaged into a cylindrical shape, was developed into a full-scale prototype for the spacesuit application. Vacuum chamber testing has been performed to characterize heat rejection as a function of inlet water temperature and water vapor back-pressure, and to show contamination resistance to the constituents expected to be found in potable water produced by the wastewater reclamation distillation processes. Other tests showed tolerance to freezing and suitability to reject heat in a Mars pressure environment. In summary, HoFi SWME is a lightweight, compact evaporator for heat rejection in the spacesuit that is robust, contamination- insensitive, freeze-tolerant, and able to reject the required heat of spacewalks in microgravity, lunar, and Martian environments. The HoFi is packaged to reject 810 W of heat through 800 hours of use in a vacuum environment, and 370 W in a Mars environment. The device also eliminates free gas and dissolved gas from the coolant loop.

Bue, Grant↗

Pathfinder Technology Demonstrator: GlobalStar Testing and Results

The communications subsystem of a spacecraft is typically a SWaP (size, weight, and power) intensive subsystem in a SWaP constrained environment such as a CubeSat. Use of a satellite-based communication system, such as GlobalStars duplex GSP-1720 radio is a low SWaP potentially game-changing low-cost communication subsystem solution that was evaluated for feasibility for the NASA Pathfinder Technology Demonstrator (PTD) project. The PTD project is a series of 6U CubeSat missions to flight demonstrate and characterize novel small satellite payloads in low Earth orbit. GlobalStar is a low Earth orbit satellite constellation for satellite phone and low-speed data communications, and the GSP-1720 is their single board duplex radio most commonly used in satellite phones and shipment tracking devices. The PTD project tested the GSP-1720 to characterize its viability for flight using NASA GEVS (General Environmental Verification Standard) vibration and thermal vacuum levels, as well as testing the uplink-downlink connectivity, data throughput, and file transfer capabilities. This presentation will present the results of the environmental and capability testing of the GSP-1720 performed at NASA Ames Research Center, as well as the viability for CubeSat use in LEO.

satellite communication↗