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NASA NTRS2003

StarBooster Demonstrator Cluster Configuration Analysis/Verification Program

In order to study the flight dynamics of the cluster configuration of two first stage boosters and upper-stage, flight-testing of subsonic sub-scale models has been undertaken using two glideback boosters launched on a center upper-stage. Three high power rockets clustered together were built and flown to demonstrate vertical launch, separation and horizontal recovery of the boosters. Although the boosters fly to conventional aircraft landing, the centerstage comes down separately under its own parachute. The goal of the project has been to collect data during separation and flight for comparison with a six degree of freedom simulation. The configuration for the delta wing canard boosters comes from a design by Starcraft Boosters, Inc. The subscale rockets were constructed of foam covered in carbon or fiberglass and were launched with commercially available solid rocket motors. The first set of boosters built were 3-ft tall with a 4-ft tall centerstage, and two additional sets of boosters were made that were each over 5-ft tall with a 7.5 ft centerstage. The rocket cluster is launched vertically, then after motor bum out the boosters are separated and flown to a horizontal landing under radio-control. An on-board data acquisition system recorded data during both the launch and glide phases of flight.

DeTurris, Dianne J.↗

NASA NTRS2004

Experimental and Numerical Correlation of Gravity Sag in Solar Sail Quality Membranes

Solar sails are among the most studied members of the ultra-lightweight and inflatable (Gossamer) space structures family due to their potential to provide propellentless propulsion. They are comprised of ultra-thin membrane panels that, to date, have proven very difficult to experimentally characterize and numerically model due to their reflectivity and flexibility, and the effects of gravity sag and air damping. Numerical models must be correlated with experimental measurements of sub-scale solar sails to verify that the models can be scaled up to represent full-sized solar sails. In this paper, the surface shapes of five horizontally supported 25 micron thick aluminized Kapton membranes were measured to a 1.0 mm resolution using photogrammetry. Several simple numerical models closely match the experimental data, proving the ability of finite element simulations to predict actual behavior of solar sails.

Black, Jonathan T.↗

NASA NTRS2004

High-speed Imaging of Global Surface Temperature Distributions on Hypersonic Ballistic-Range Projectiles

The NASA-Ames ballistic range provides a unique capability for aerothermodynamic testing of configurations in hypersonic, real-gas, free-flight environments. The facility can closely simulate conditions at any point along practically any trajectory of interest experienced by a spacecraft entering an atmosphere. Sub-scale models of blunt atmospheric entry vehicles are accelerated by a two-stage light-gas gun to speeds as high as 20 times the speed of sound to fly ballistic trajectories through an 24 m long vacuum-rated test section. The test-section pressure (effective altitude), the launch velocity of the model (flight Mach number), and the test-section working gas (planetary atmosphere) are independently variable. The model travels at hypersonic speeds through a quiescent test gas, creating a strong bow-shock wave and real-gas effects that closely match conditions achieved during actual atmospheric entry. The challenge with ballistic range experiments is to obtain quantitative surface measurements from a model traveling at hypersonic speeds. The models are relatively small (less than 3.8 cm in diameter), which limits the spatial resolution possible with surface mounted sensors. Furthermore, since the model is in flight, surface-mounted sensors require some form of on-board telemetry, which must survive the massive acceleration loads experienced during launch (up to 500,000 gravities). Finally, the model and any on-board instrumentation will be destroyed at the terminal wall of the range. For these reasons, optical measurement techniques are the most practical means of acquiring data. High-speed thermal imaging has been employed in the Ames ballistic range to measure global surface temperature distributions and to visualize the onset of transition to turbulent-flow on the forward regions of hypersonic blunt bodies. Both visible wavelength and infrared high-speed cameras are in use. The visible wavelength cameras are intensified CCD imagers capable of integration times as short as 2 ns. The infrared camera uses an Indium Antimonide (InSb) sensor in the 3 to 5 micron band and is capable of integration times as short as 500 ns. The projectiles are imaged nearly head-on using expendable mirrors offset slightly from the flight path. The proposed paper will discuss the application of high-speed digital imaging systems in the NASA-Ames hypersonic ballistic range, and the challenges encountered when applying these systems. Example images of the thermal radiation from the blunt nose of projectiles flying at nearly 14 times the speed of sound will be given.

Wilder, Michael C.↗

NASA NTRS2004

Experimental, Theoretical, and Computational Investigation of Separated Nozzle Flows

A detailed experimental, theoretical, and computational study of separated nozzle flows has been conducted. Experimental testing was performed at the NASA Langley 16-Foot Transonic Tunnel Complex. As part of a comprehensive static performance investigation, force, moment, and pressure measurements were made and schlieren flow visualization was obtained for a sub-scale, non-axisymmetric, two-dimensional, convergent- divergent nozzle. In addition, two-dimensional numerical simulations were run using the computational fluid dynamics code PAB3D with two-equation turbulence closure and algebraic Reynolds stress modeling. For reference, experimental and computational results were compared with theoretical predictions based on one-dimensional gas dynamics and an approximate integral momentum boundary layer method. Experimental results from this study indicate that off-design overexpanded nozzle flow was dominated by shock induced boundary layer separation, which was divided into two distinct flow regimes; three- dimensional separation with partial reattachment, and fully detached two-dimensional separation. The test nozzle was observed to go through a marked transition in passing from one regime to the other. In all cases, separation provided a significant increase in static thrust efficiency compared to the ideal prediction. Results indicate that with controlled separation, the entire overexpanded range of nozzle performance would be within 10% of the peak thrust efficiency. By offering savings in weight and complexity over a conventional mechanical exhaust system, this may allow a fixed geometry nozzle to cover an entire flight envelope. The computational simulation was in excellent agreement with experimental data over most of the test range, and did a good job of modeling internal flow and thrust performance. An exception occurred at low nozzle pressure ratios, where the two-dimensional computational model was inconsistent with the three-dimensional separation observed in the experiment. In general, the computation captured the physics of the shock boundary layer interaction and shock induced boundary layer separation in the nozzle, though there were some differences in shock structure compared to experiment. Though minor, these differences could be important for studies involving flow control or thrust vectoring of separated nozzles. Combined with other observations, this indicates that more detailed, three-dimensional computational modeling needs to be conducted to more realistically simulate shock-separated nozzle flows.

Hunter, Craig A.↗

NASA NTRS1998

Recent Dynamic Measurements and Considerations for Aerodynamic Modeling of Fighter Airplane Configurations

As airplane designs have trended toward the expansion of flight envelopes into the high angle of attack and high angular rate regimes, concerns regarding modeling the complex unsteady aerodynamics for simulation have arisen. Most current modeling methods still rely on traditional body axis damping coefficients that are measured using techniques which were intended for relatively benign flight conditions. This paper presents recent wind tunnel results obtained during large-amplitude pitch, roll and yaw testing of several fighter airplane configurations. A review of the similitude requirements for applying sub-scale test results to full-scale conditions is presented. Data is then shown to be a strong function of Strouhal number - both the traditional damping terms, but also the associated static stability terms. Additionally, large effects of sideslip are seen in the damping parameter that should be included in simulation math models. Finally, an example of the inclusion of frequency effects on the data in a simulation is shown.

Brandon, Jay M.↗

NASA NTRS1997

Fluidic Thrust Vectoring of an Axisymmetric Exhaust Nozzle at Static Conditions

A sub-scale experimental static investigation of an axisymmetric nozzle with fluidic injection for thrust vectoring was conducted at the NASA Langley Jet Exit Test Facility. Fluidic injection was introduced through flush-mounted injection ports in the divergent section. Geometric variables included injection-port geometry and location. Test conditions included a range of nozzle pressure ratios from 2 to 10 and a range of injection total pressure ratio from no-flow to 1.5. The results indicate that fluidic injection in an axisymmetric nozzle operating at design conditions produced significant thrust-vector angles with less reduction in thrust efficiency than that of a fluidically-vectored rectangular jet. The axisymmetric geometry promoted a pressure relief mechanism around the injection slot, thereby reducing the strength of the oblique shock and the losses associated with it. Injection port geometry had minimal effect on thrust vectoring.

Wing, David J.↗

NASA NTRS2004

Numerical Investigation of Dual-Mode Scramjet Combustor with Large Upstream Interaction

Dual-mode scramjet combustor configuration with significant upstream interaction is investigated numerically, The possibility of scaling the domain to accelerate the convergence and reduce the computational time is explored. The supersonic combustor configuration was selected to provide an understanding of key features of upstream interaction and to identify physical and numerical issues relating to modeling of dual-mode configurations. The numerical analysis was performed with vitiated air at freestream Math number of 2.5 using hydrogen as the sonic injectant. Results are presented for two-dimensional models and a three-dimensional jet-to-jet symmetric geometry. Comparisons are made with experimental results. Two-dimensional and three-dimensional results show substantial oblique shock train reaching upstream of the fuel injectors. Flow characteristics slow numerical convergence, while the upstream interaction slowly increases with further iterations. As the flow field develops, the symmetric assumption breaks down. A large separation zone develops and extends further upstream of the step. This asymmetric flow structure is not seen in the experimental data. Results obtained using a sub-scale domain (both two-dimensional and three-dimensional) qualitatively recover the flow physics obtained from full-scale simulations. All results show that numerical modeling using a scaled geometry provides good agreement with full-scale numerical results and experimental results for this configuration. This study supports the argument that numerical scaling is useful in simulating dual-mode scramjet combustor flowfields and could provide an excellent convergence acceleration technique for dual-mode simulations.

Mohieldin, T. O.↗

NASA NTRS2005

Finite Element Analysis and Test Correlation of a 10-Meter Inflation-Deployed Solar Sail

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA's future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive phased test plan is currently being implemented to advance the technology readiness level of the solar sail design. These tests consist of solar sail component, subsystem, and sub-scale system ground tests that simulate the vacuum and thermal conditions of the space environment. Recently, two solar sail test articles, a 7.4-m beam assembly subsystem test article and a 10-m four-quadrant solar sail system test article, were tested in vacuum conditions with a gravity-offload system to mitigate the effects of gravity. This paper presents the structural analyses simulating the ground tests and the correlation of the analyses with the test results. For programmatic risk reduction, a two-prong analysis approach was undertaken in which two separate teams independently developed computational models of the solar sail test articles using the finite element analysis software packages: NEiNastran and ABAQUS. This paper compares the pre-test and post-test analysis predictions from both software packages with the test data including load-deflection curves from static load tests, and vibration frequencies and mode shapes from vibration tests. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were uncertainties in the material properties, test conditions, and modeling assumptions used in the analyses.

Sleight, David W.↗

NASA NTRS2004

Epoxy Adhesives for Stator Magnet Assembly in Stirling Radioisotope Generators (SRG)

As NASA seeks to fulfill its goals of exploration and understanding through missions planned to visit the moons of Saturn and beyond, a number of challenges arise from the idea of deep space flight. One of the first problems associated with deep space travel is electrical power production for systems on the spacecraft. Conventional methods such as solar power are not practical because efficiency decreases substantially as the craft moves away from the Sun. The criterion for power generation during deep space missions are very specific, the main points requiring high reliability, low mass, minimal vibration and a long lifespan. A Stirling generator, although fairly old in concept, is considered to be a potential solution for electrical power generation for deep space flight. A Stirling generator works on the same electromagnetic principles of a standard generator, using the linear motion of the alternator through the stationary stator which produces electric induction. The motion of the alternator, however, is produced by the heating and cooling dynamics of pressurized gases. Essentially heating one end and cooling another of a contained gas will cause a periodic expansion and compression of the gas from one side to the other, which a displacer translates into linear mechanical motion. NASA needs to confirm that the materials used in the generator will be able to withstand the rigors of space and the life expectancy of the mission. I am working on the verification of the epoxy adhesives used to bond magnets to the steel lamination stack to complete the stator; in terms of in-service performance and durability under various space environments. Understanding the proper curing conditions, high temperature properties, and degassing problems as well as production difficulties are crucial to the long term success of the generator. system and steel substrate used in the stator. To optimize the curing conditions of the epoxies, modulated differential scanning calorimetry analysis was done as a function of cure time and temperatures. Adhesion bond strength was tested at various temperatures with lap shear samples using Hiperco 50 substrate to ensure that the proper adhesive is being used. To try and solve the problem of bondline thickness, micro glass beads of 0.0017" in diameter were investigated to see if any other physical properties of the epoxy were affected. Efforts will be made to develop a standard, optimized, fabrication process/procedure of sub-scale magnet-stator assemblies for various adhesive performance evaluation studies under simulated generator conditions. Also, accelerated aging testing will be done in a pressurized canister with stator assembly samples for three years to verify if any degassing or thermal degradation of the epoxy occurs. The necessity of verifying the correct epoxy adhesive system for the stator magnet in the SRG is crucial because failure of the stator assembly would jeopardize the electrical system, and thereby the entire mission itself. My work involves specimen fabrications, testing, and data analyses of the epoxy adhesive system for the stator magnet in the SRG is crucial because failure of the stator assembly would jeopardize the electrical system, and thereby the entire mission itself.

Cater, George M.↗

NASA NTRS2004

Vibration-Based Data Used to Detect Cracks in Rotating Disks

Rotor health monitoring and online damage detection are increasingly gaining the interest of aircraft engine manufacturers. This is primarily due to the fact that there is a necessity for improved safety during operation as well as a need for lower maintenance costs. Applied techniques for the damage detection and health monitoring of rotors are essential for engine safety, reliability, and life prediction. Recently, the United States set the ambitious goal of reducing the fatal accident rate for commercial aviation by 80 percent within 10 years. In turn, NASA, in collaboration with the Federal Aviation Administration, other Federal agencies, universities, and the airline and aircraft industries, responded by developing the Aviation Safety Program. This program provides research and technology products needed to help the aerospace industry achieve their aviation safety goal. The Nondestructive Evaluation (NDE) Group of the Optical Instrumentation Technology Branch at the NASA Glenn Research Center is currently developing propulsion-system-specific technologies to detect damage prior to catastrophe under the propulsion health management task. Currently, the NDE group is assessing the feasibility of utilizing real-time vibration data to detect cracks in turbine disks. The data are obtained from radial blade-tip clearance and shaft-clearance measurements made using capacitive or eddy-current probes. The concept is based on the fact that disk cracks distort the strain field within the component. This, in turn, causes a small deformation in the disk's geometry as well as a possible change in the system's center of mass. The geometric change and the center of mass shift can be indirectly characterized by monitoring the amplitude and phase of the first harmonic (i.e., the 1 component) of the vibration data. Spin pit experiments and full-scale engine tests have been conducted while monitoring for crack growth with this detection methodology. Even so, published data are extremely limited, and the basic foundation of the methodology has not been fully studied. The NDE group is working on developing this foundation on the basis of theoretical modeling as well as experimental data by using the newly constructed subscale spin system shown in the preceding photograph. This, in turn, involved designing an optimal sub-scale disk that was meant to represent a full-scale turbine disk; conducting finite element analyses of undamaged and damaged disks to define the disk's deformation and the resulting shift in center of mass; and creating a rotordynamic model of the complete disk and shaft assembly to confirm operation beyond the first critical concerning the subscale experimental setup. The finite element analysis data, defining the center of mass shift due to disk damage, are shown. As an example, the change in the center of mass for a disk spinning at 8000 rpm with a 0.963-in. notch was 1.3 x 10(exp -4) in. The actual vibration response of an undamaged disk as well as the theoretical response of a cracked disk is shown. Experiments with cracked disks are continuing, and new approaches for analyzing the captured vibration data are being developed to better detect damage in a rotor. In addition, the subscale spin system is being used to test the durability and sensitivity of new NDE sensors that focus on detecting localized damage. This is designed to supplement the global response of the crack-detection methodology described here.

Gyekenyesi, Andrew L.↗

NASA NTRS2005

Structural Analysis of an Inflation-Deployed Solar Sail With Experimental Validation

Under the direction of the NASA In-Space Propulsion Technology Office, the team of L Garde, NASA Jet Propulsion Laboratory, Ball Aerospace, and NASA Langley Research Center has been developing a scalable solar sail configuration to address NASA s future space propulsion needs. Prior to a flight experiment of a full-scale solar sail, a comprehensive phased test plan is currently being implemented to advance the technology readiness level of the solar sail design. These tests consist of solar sail component, subsystem, and sub-scale system ground tests that simulate the vacuum and thermal conditions of the space environment. Recently, two solar sail test articles, a 7.4-m beam assembly subsystem test article and a 10-m four-quadrant solar sail system test article, were tested in vacuum conditions with a gravity-offload system to mitigate the effects of gravity. This paper presents the structural analyses simulating the ground tests and the correlation of the analyses with the test results. For programmatic risk reduction, a two-prong analysis approach was undertaken in which two separate teams independently developed computational models of the solar sail test articles using the finite element analysis software packages: NEiNastran and ABAQUS. This paper compares the pre-test and post-test analysis predictions from both software packages with the test data including load-deflection curves from static load tests, and vibration frequencies and mode shapes from structural dynamics tests. The analysis predictions were in reasonable agreement with the test data. Factors that precluded better correlation of the analyses and the tests were uncertainties in the material properties, test conditions, and modeling assumptions used in the analyses.

Sleight, David W.↗

NASA NTRS2005

Simulations of a Liquid Hydrogen Inducer at Low-Flow Off-Design Flow Conditions

The ability to accurately model details of inlet back flow for inducers operating a t low-flow, off-design conditions is evaluated. A sub-scale version of a three-bladed liquid hydrogen inducer tested in water with detailed velocity and pressure measurements is used as a numerical test bed. Under low-flow, off-design conditions the length of the separation zone as well as the swirl velocity magnitude was under predicted with a standard k-E model. When the turbulent viscosity coefficient was reduced good comparison was obtained a t all the flow conditions examined with both the magnitude and shape of the profile matching well with the experimental data taken half a diameter upstream of the leading edge. The velocity profiles and incidence angles a t the leading edge itself were less sensitive to the back flow length predictions indicating that single-phase performance predictions may be well predicted even if the details of flow separation modeled are incorrect. However, for cavitating flow situations the prediction of the correct swirl in the back flow and the pressure depression in the core becomes critical since it leads to vapor formation. The simulations have been performed using the CRUNCH CFD(Registered Trademark) code that has a generalized multi-element unstructured framework and a n advanced multi-phase formulation for cryogenic fluids. The framework has been validated rigorously for predictions of temperature and pressure depression in cryogenic fluid cavities and has also been shown to predict the cavitation breakdown point for inducers a t design conditions.

Hosangadi, A.↗

NASA NTRS2005

Chapter 19B - Antenna Radiation Patterns

Modern civil and military aircraft are equipped with a variety of communication devices, radio navigation equipment, and air traffic control systems. For all of these devices appropriate antennas must be available to transmit and receive the signals. As a result, as many as 30 antennas, and sometimes even more, are mounted around today's aircraft. For this reason, it is necessary to know the capabilities of the receiving/transmitting equipment on board. These capabilities are driven by the antenna characteristics. Therefore, coverage, shading, and beam pointing pattern data are necessary for optimum electronic coverage. The aircraft antenna has to convert the available power density of the electromagnetic field to an electric voltage at its connector. This voltage level must be sufficiently high to operate the connected equipment. The reciprocity principle states that it makes no difference if the antenna is receiving or transmitting. For the certification of the aircraft antennas it must be proven that the antennas are at least generating the minimum receiver input voltage which is required for each radio service. The prime condition is, of course, that the specified field power densities of the different radio navigation and communication services are available. An important property of a radio frequency link is the electro-magnetic field intensity at every point in space for a given output power of the antenna. As the propagation of radio frequency waves in free space is well known, the spatial distribution of the field intensity needs only be measured at one spatial sphere around the antenna. The information is usually given as distributions along the circumference of flat sections through this sphere: each of these is called an ARP. Several ARPs are usually required to describe the complete spatial antenna pattern of an antenna. In addition to mathematical modeling, measurements on sub-scale models, and static measurements on full size models or aircraft on the ground, dynamic measurements on aircraft in flight play the most important role in the aircraft antenna testing and certification. [19B-1] The shape of an ARP, for one given frequency, is determined by the shape of the antenna and the shape and material of the surface it is mounted on. As the directly transmitted waves interfere with waves reflected by the aircraft skin with its complex geometry, and the surface material parameters are only roughly known, it is not possible to predict the ARP with the required accuracy. In ground measurements the earth's surface also acts as a reflector thereby causing the ground ARP to be different from the in-flight ARP. As the in-flight ARP is the ARP we are actually interested in it becomes clear that it is necessary to conduct in-flight ARP measurements. The Flight Test Engineer must be aware of the needs of the specialists who are establishing the test program for measuring antenna patterns and radar cross sections. These tests will require special test equipment and dedicated flights to obtain the data that they require. This Section provides an introduction to the principles of determining antenna patterns and the flight techniques for determining both antenna patterns and radar cross section. Reference 19B-1 provides detailed information.

Helmut Bothe↗

NASA NTRS2001

Disk Alloy Development

The advanced powder metallurgy disk alloy ME3 was designed using statistical screening and optimization of composition and processing variables in the NASA HSR/EPM disk program to have extended durability at 1150 to 1250 "Fin large disks. Scaled-up disks of this alloy were produced at the conclusion of this program to demonstrate these properties in realistic disk shapes. The objective of the UEET disk program was to assess the mechanical properties of these ME3 disks as functions of temperature, in order to estimate the maximum temperature capabilities of this advanced alloy. Scaled-up disks processed in the HSR/EPM Compressor / Turbine Disk program were sectioned, machined into specimens, and tested in tensile, creep, fatigue, and fatigue crack growth tests by NASA Glenn Research Center, in cooperation with General Electric Engine Company and Pratt & Whitney Aircraft Engines. Additional sub-scale disks and blanks were processed and tested to explore the effects of several processing variations on mechanical properties. Scaled-up disks of an advanced regional disk alloy, Alloy 10, were used to evaluate dual microstructure heat treatments. This allowed demonstration of an improved balance of properties in disks with higher strength and fatigue resistance in the bores and higher creep and dwell fatigue crack growth resistance in the rims. Results indicate the baseline ME3 alloy and process has 1300 to 1350 O F temperature capabilities, dependent on detailed disk and engine design property requirements. Chemistry and process enhancements show promise for further increasing temperature capabilities.

Gabb, Tim↗

NASA NTRS2005

Experimental Validation: Subscale Aircraft Ground Facilities and Integrated Test Capability

Experimental testing is an important aspect of validating complex integrated safety critical aircraft technologies. The Airborne Subscale Transport Aircraft Research (AirSTAR) Testbed is being developed at NASA Langley to validate technologies under conditions that cannot be flight validated with full-scale vehicles. The AirSTAR capability comprises a series of flying sub-scale models, associated ground-support equipment, and a base research station at NASA Langley. The subscale model capability utilizes a generic 5.5% scaled transport class vehicle known as the Generic Transport Model (GTM). The AirSTAR Ground Facilities encompass the hardware and software infrastructure necessary to provide comprehensive support services for the GTM testbed. The ground facilities support remote piloting of the GTM aircraft, and include all subsystems required for data/video telemetry, experimental flight control algorithm implementation and evaluation, GTM simulation, data recording/archiving, and audio communications. The ground facilities include a self-contained, motorized vehicle serving as a mobile research command/operations center, capable of deployment to remote sites when conducting GTM flight experiments. The ground facilities also include a laboratory based at NASA LaRC providing near identical capabilities as the mobile command/operations center, as well as the capability to receive data/video/audio from, and send data/audio to the mobile command/operations center during GTM flight experiments.

Bailey, Roger M.↗

NASA NTRS2004

HiPEP Ion Optics System Evaluation Using Gridlets

Experimental measurements are presented for sub-scale ion optics systems comprised of 7 and 19 aperture pairs with geometrical features that are similar to the HiPEP ion optics system. Effects of hole diameter and grid-to-grid spacing are presented as functions of applied voltage and beamlet current. Recommendations are made for the beamlet current range where the ion optics system can be safely operated without experiencing direct impingement of high energy ions on the accelerator grid surface. Measurements are also presented of the accelerator grid voltage where beam plasma electrons backstream through the ion optics system. Results of numerical simulations obtained with the ffx code are compared to both the impingement limit and backstreaming measurements. An emphasis is placed on identifying differences between measurements and simulation predictions to highlight areas where more research is needed. Relatively large effects are observed in simulations when the discharge chamber plasma properties and ion optics geometry are varied. Parameters investigated using simulations include the applied voltages, grid spacing, hole-to-hole spacing, doubles-to-singles ratio, plasma potential, and electron temperature; and estimates are provided for the sensitivity of impingement limits on these parameters.

Willliams, John D.↗

NASA NTRSDate not supplied

Evaluation of Low-Energy Hydrogen Separation Method Using Metal-Organic Frameworks (MOFs) for Closed-Loop ECLSS Air Revitalization (CLEAR)

The State-of-the-Art (SOA) air revitalization architecture onboard the International Space Station (ISS) recovered approximately 50% of the oxygen (O 2 ) from metabolic carbon dioxide (CO 2 ) via the Sabatier process from 2011 to 2017. O 2 recovery is currently constrained by the limited availability of reactant hydrogen (H 2 ) preventing complete conversion of CO 2 to H 2 O. Increasing O 2 recovery within Closed-Loop ECLSS is essential to reducing resupply mass for long-duration manned missions; specifically focusing on water (H 2 O) which supplies H 2 for Sabatier via water electrolysis. Past ground test endeavors at Marshall Space Flight Center (MSFC) have attempted to recover H 2 from Sabatier-produced CH 4 using technologies such as carbon vapor deposition (CVD) and plasma pyrolysis. The byproducts of these technologies can act as a catalyst poison or reactor deadload to the Sabatier reactor. Hydrogen separation techniques must be utilized to maintain the Sabatier catalyst during gas recycling and must be scalable, non-energy intensive, and safe to operate in a habitation setting. Research indicated that metal-organic frameworks (MOFs) could meet these criteria and were tested for their capability to capture the various carbon-based gaseous products of CVD and plasma pyrolysis such as acetylene (C 2 H 2 ), ethylene (C 2 H 4 ), ethane (C 2 H 6 ), and carbon monoxide (CO) which would purify the hydrogen gas stream passing through the MOF. A sub-scale adsorption column was developed by Marshall Space Flight Center to test three MOF candidates against a synthetic gas mixture comprised of process-relevant carbonous gases and hydrogen to evaluate the separation capability of the MOFs. The results of the hydrogen separation capability, isothermal desorption capability, and demonstrated cyclic reuse of the MOF are presented in this paper.

Kagen Crawford↗

NASA NTRSDate not supplied

Numerical Investigation of Heat Transfer and Fluid Flow within Electrochemical Hydrogen Peroxide Generation Unit

Long-term manned space missions require the onboard production of disinfectants essential for maintaining crew health and supporting life systems. Currently, disinfection aboard the International Space Station (ISS) relies on disposable wetted wipes, which are regularly resupplied from Earth. This approach imposes a significant burden on resupply logistics, storage, and waste management. To address these challenges and support future missions, efforts are underway to develop an in-situ solution that electrochemically generates hydrogen peroxide disinfectant using onboard resources. In collaboration with NASA, Faraday Technology, Inc. has advanced this concept through a series of Small Business Innovation Research (SBIR) projects, resulting in the development of a Peroxide Generation Unit (PGU). The PGU can produce up to 3 wt.% hydrogen peroxide on-demand at a rate of 1 liter per day, providing a sustainable alternative to Earth-dependent supplies. The resulting aqueous hydrogen peroxide (H₂O₂) is an effective disinfectant, safe for crew use, compatible with spacecraft systems, and free from volatiles, off-gassing, or residues. This innovation offers a reliable, efficient solution for onboard disinfection, reducing dependence on Earth-based resupply while ensuring the health and safety of space crews. Generating hydrogen peroxide at the required rate needs high voltages and currents, exceeding 20V and 2A respectively, which leads to significant heat generation from Joule heating. This temperature rise poses a risk to sensitive system components, especially critical and expensive membranes that can degrade under thermal stress. To mitigate this risk, the thermal, fluid, and electrical flows within the system are modeled computationally using the commercial software COMSOL. The numerical simulations are validated against experimental data from both sub-scale and alpha-scale systems. Once verified, the model is employed to identify thermal hotspots, investigate their underlying causes, and explore solutions to prevent them.

Life Support Systems (LSS)↗