SEARCH · Engineering Papers

Results for “harsh environments”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,063 records · Page 59

All sources NASA NTRS DOE OSTI

NASA NTRS2023

Protective Coatings for Lunar Dust Tolerance

Materials capable of withstanding the harsh lunar environment are critically needed to support long duration, sustainable missions on the Moon’s surface. Lunar dust significantly threatens the durability and reusability of components and vehicles due to possessing a fine, jagged morphology and highly abrasive nature. These characteristics result in the particles eroding, adhering and/or embedding onto component surfaces and into device confined geometries (e.g., gear housing, interlocking systems, etc.) potentially leading to premature failure. The aim of this study is to identify and characterize wear-resistant commercial-off-the-shelf (COTS) materials, including advanced ceramics, for use as protective coatings to minimize abrasion and adhesion caused by lunar dust. Preliminary testing that mimics various aspects of lunar dust degradation, such as abrasive wear and adhesion, suggests that COTS ceramic coatings can improve lunar dust tolerance and protect underlying metallic substrates.

Valerie. L. Wiesner↗

NASA NTRS2022

Power Converter Design for the Europa Lander Motor Controller

This paper will outline the design and test results for the Europa Lander motor controller’s Power Conversion Slice. Europa Lander is a proposed NASA mission concept to send a stationary spacecraft to Jupiter’s Icy Moon, Europa, to search for subsurface biosignatures. The Power Conversion Card is one of the many technologies designed for this mission. The Power Conversion Card’s primary function is to convert the power supplied by the spacecraft battery to usable power for use within the motor controller. In addition, this card provides power system telemetry to the spacecraft computer. This card tolerates Europa’s harsh radiation environment within a protected vault to enable it to survive the external temperatures which can be as low as -184°C during the three-week mission. This design makes use of multiple commercially available radiation hardened electronics, including Cobham’s UT32M0R500 Arm Microcontroller along with VPT’s DC-DC Converters for power conversion. The microcontroller is used to collect local power system telemetry and assess card health autonomously without intervention from the spacecraft’s main computer. This paper will showcase the design behind the prototype and electrical testing results.

Lias, Malcolm↗

NASA NTRSDate not supplied

Thermal Management Challenges and Technology Options for Lunar Regenerative Fuel Cells

Regenerative Fuel Cells (RFCs) enable lunar surface hardware, from pressurized rovers to surface habitats, to survive the lunar night by providing the required energy storage with a lower mass than state of the art battery systems. RFCs consist of fuel cell and electrolyzer electrochemical stack(s), a fluidic balance of plant, and electrical balance of plant. Fuel cells operate by converting the stored chemical energy of reactants into DC electrical power, heat, and water. When supplied DC power from an available external source, electrolyzers regenerate the reactants through electrolysis. The balance of plant is a critical part of the integrated system consisting of many individual components and provides fluid pressure management and conditioning, fluid storage, and thermal management. Component technology development is required to create an RFC system that will be capable of surviving the harsh lunar environment and maximize specific energy (W-hr/kg). One critical component requiring development includes a kW-scale high flux thermal switch. The primary requirement for the thermal switch is the ability to maintain low thermal resistance with the RFC heat rejection interface during the lunar day to maximize heat rejection while switching to a high thermal resistance during the lunar night such that the RFC can conserve as much thermal energy as possible. Different technology including freeze tolerant pumped loop, passive louvers, and variable conductance heat pipes were assessed as potential solutions. NASA is exploring development options through internal and external partnerships to develop this technology critical for a spaceflight RFC system.

Energy Storage↗

NASA NTRSDate not supplied

Measuring the Wear and Abrasive Resistance of Air Plasma Sprayed Aluminum Oxide for Lunar Exploration

Lunar regolith, especially finer dust particles traveling at high velocities, can cause significant wear and abrasive damage to structural components that ensure a prolongated presence on the surface of the Moon. With the absence of an atmosphere and lower gravity than on Earth, regolith particles maintain high velocities at large distances from where they were generated, for example next to lunar landers. Wear-resistant ceramic and ceramic composite materials can improve the durability of spacecraft components during long missions on the Moon’s surface. Aluminum oxide coatings are lightweight, have multifunctional properties, and have high strength including high hardness and wear resistance. These properties can help improve the durability of structures used in space exploration. Air plasma sprayed (APS) aluminum oxide coatings have demonstrated the potential to protect critical structures. This study investigated the abrasive wear resistance of APS aluminum oxide coatings via Taber abrasion experiments. Taber abrasion offers the advantage of quantifying the abrasive wear behavior of particles with different shapes on a surface. In this work, an abrasive wheel made of silicon carbide was utilized to evaluate wear properties of specimens progressively over 5000 cycles. This experiment focused on testing two series of specimens to determine whether a bond coat composed of nickel, chromium, aluminum, and yttrium (NiCrAlY) improved the protective behavior of the APS aluminum oxide coating. The specimens varied in topcoat thickness and were made with and without an approximately 100 µm bond coat layer. The mass of the specimens was measured at 400 cycles, 800 cycles, 3800 cycles, and 5000 cycles. Increasing thickness was found to result in higher wear for samples with and without a bond coat. Increased mass loss in samples with a bond coat was observed indicating a need for further studies on the overall impact of the use of a bond coat on the protective behavior of the coatings. To continue designing wear resistant coatings for structural protection in space missions, the multifunctional properties of the APS aluminum oxide coating will be studied. Future experiments will determine whether the APS aluminum oxide coating can protect the structures from other aspects of the harsh space environment, such as extreme temperature variations and ionizing radiation.

aluminum oxide↗

NASA NTRSDate not supplied

Overview of the MISSE-16 Mission and Preliminary Characterization of Novel Space Weathered Materials

The Materials International Space Station Experiment (MISSE) project is a series of experiments that began in 2001, involving the deployment of external experiment platforms on the International Space Station (ISS). Since then, more than 4,000 materials were tested yielding valuable data and insights into the performance of materials and coatings in the harsh space environment, as well as providing a platform for testing and validating new materials and technologies. The results of the MISSE experiments have contributed to the development of more durable and reliable spacecraft and equipment, as well as improving our understanding of the space environment and its effects on human space exploration. To gain deeper insights into the changes in material properties of both novel and heritage spacecraft materials over the course of a mission, we proposed to enhance the MISSE hardware. This was achieved by integrating a high-resolution camera that can capture both RGB and IR color data, along with an updated illumination scheme. The identical sets of selected materials were mounted on the Zenith, Ram, and Wake faces of the ISS to expose them to predominant vacuum ultraviolet (VUV), atomic oxygen, and high-energy electron conditions. In addition, we exposed flight duplicates of these materials to a simulated space environment, which included sequential exposure to the same irradiation species on the ground. This allowed us to study the effects of space exposure on the materials in a controlled manner and to compare their behavior in both real and simulated space environments. The MISSE-FF flight sample collection comprised different classes of polymers, including polyimides from the Kapton family, manufactured by E.I du Pont de Nemours and Co., Polyethylene terephthalate (PET) materials, liquid crystal polymers, PI/Polyhedral Oligomeric Silsesquioxanes (POSS), and carbon and glass fiber reinforced polymers. The experimental cadence during the MISSE-16 mission (~6 months) included daily images of each sample for the first week, weekly for the next 2 months, and monthly the remaining duration of the mission. This paper will focus on the flight duplicate as well as the postflight optical characterization of novel and heritage materials currently under observation on the MISSE-FF.

Jainisha R Shah↗

NASA NTRS2024

Investigating Sulfur-Rich Mercury Analogs Exposed to Simulated Micrometeoroid Bombardment in the Laboratory

Space weathering (SW) continually alters the spectral, microstructural, and chemical characteristics of the surface of airless bodies across the solar system. The effects of SW vary depending on the heliocentric distance and the initial composition of the target surface. While SW on the Moon and S-type asteroids is well documented, our understanding of how this process affects Mercury is at an early stage. Mercury’s interplanetary environment is harsh, with the surface of the planet experiencing an intense solar wind flux as well as a higher flux and velocity of micrometeoroid impactors compared to the Moon and S-type asteroids. In addition, Mercury is also a geochemical endmember, with a surface composition low in Fe (<2 wt.%) and enriched in volatile components, such as sulfur (up to 4 wt.% in the low reflectance material (LRM)). These volatile components are thought to play a major role in the formation of hollows via their sublimation. Sulfur has been hypothesized to occur at the surface of Mercury as sulfide minerals (MgS, CaS) based on its correlation with Mg and Ca in remote sensing data. However, recent observations of chaotic terrains in the north polar area of Mercury and of glacier-like features at lower latitudes indicated that octasulfur (S 8 , elemental sulfur) is another likely constituent of a volatile-rich layer in Mercury’s crust. Its behavior on Mercury may result in a complex cycle of enrichment and depletion. While S is often depleted on small body surfaces, Mercury’s gravity could result in ejected S subsequently returning to the surface and coating regolith grains. Further, the reaction of reduced S-rich gas with glasses of a Mercury-like composition also produced S-rich coatings. However, the precise behavior and evolution of S-rich species exposed to the harsh SW on Mercury remains poorly understood and needs to be further investigated in the laboratory. Here, we present the results of our analyses of the spectral, microstructural, and chemical characteristics of S-rich Mercury analogs irradiated by pulsed laser to simulate the short duration, high temperature events associated with micrometeoroid impacts.

N Bott↗

NASA NTRSDate not supplied

Maps of Primary Radiatoin Dose Around the Lunar South Pole: Preliminary Assessment of Artemis Landing Sites

The Moon has a harsh radiation environment that poses significant challenges to future science and exploration activities. Exposure hazards from space radiation are primarily due to galactic cosmic rays (GCRs) and solar energetic particles (SEPs) that are incident at the lunar surface from all directions. The Lunar Reconnaissance Orbiter’s (LRO) Cosmic Ray Telescope for Effects of Radiation (CRaTER) instrument has been observing space radiation around the Moon since 2009. The CRaTER observations show a steady GCR flux with intermittent SEP events that have much higher fluxes. During solar minimum, the GCR flux is higher, while the SEP events are less common. On the other hand, during solar maximum, the SEP events have are more frequent and the GCR flux is lower. This is due to variations in solar activity. GCRs have characteristic energies spanning from 1 MeV to 10s of GeV. SEPs, however, have much lower energy ranges of 50 keV to 100s of MeV.

P. H Phipps↗

NASA NTRSDate not supplied

Thermal Performance of Perovskite-Based Photovoltaics for Operation in Low Earth Orbit

Perovskite-based photovoltaics are attractive for applications in space. The space environment is harsh with extreme temperatures, atomic oxygen, ionizing radiation, UV radiation, and thermal cycling. Here, we evaluate the thermal performance of a perovskite active layer and perovskite photovoltaic devices in low earth orbit. We determine that a 1 µm layer of silicon oxide coupled with a 500 nm zirconia thin film aid in cell thermal management. We model the residual stresses between various layers in the device and prove that thermally induced mechanical failure of the perovskite (t > 460 years) is unlikely during the operating lifetime of a space mission. We identify target power conversion efficiencies to manage operating temperature of a perovskite-based photovoltaic.

Timothy S. Krause↗

NASA NTRS2024

Towards Autonomous Surface Missions on Ocean Worlds

Through advanced autonomy testbed programs, NASA is setting the groundwork for one of its top priorities—the search for signs of life and potentially habitable bodies in our solar system and beyond. The prime destinations for such exploration are bodies containing liquid water, such as Jupiter’s moon Europa and Saturn’s moon Enceladus. Initial missions to these “ocean worlds” will be robotic and require a high degree of onboard autonomy due to long Earth-communication lags and blackouts, harsh surface environments, and limited battery life.

Khalil Michael Dalal↗

NASA NTRSDate not supplied

Wear-Resistance Investigations on Ceramic Coatings for Lunar Dust Mitigation

Lunar dust has posed a major challenge to exploration efforts due to abrasion and impact. This work focuses on fundamental studies on ceramic coatings as candidates for enhanced resistance to impact and wear. As a first step, standard and modified approaches to the method of abrasion testing were explored for options to incorporate lunar regolith as wear media, the effects of which were presented for AL6061-T6 control samples. Following this, wear results for air plasma-sprayed (APS) alumina coatings were investigated due to their superior strength and surface hardness. In addition, APS 8 wt % yttria-stabilized zirconia (8YSZ) coatings were studied for their strength and martensitic transformation toughness. Measurements were made by assessing the mass loss, with a standard scale at various intervals. In addition, surface roughness was measured with a profilometer and features identified with a high-resolution microscope. The findings demonstrated that wear media has a distinct effect on the abrasion. The alumina coatings demonstrated improved wear over 8YSZ. However, the tailorability of 8YSZ makes it an attractive option to continue to modify as a wear-resistant coating to protect against lunar dust abrasion. The results of these measurements provide insight into the wear behavior of future directions in candidate ceramic coatings for the harsh lunar environment.

ceramic coatings↗

NASA NTRSDate not supplied

Wear-Resistance Investigations on Ceramic Coatings for Lunar Dust Mitigation

ceramic coatings↗

NASA NTRS2024

Organic Products of Fatty Acid and Magnesium Sulfate Mixtures after Gamma Radiolysis: Implications for Missions to Europa

If ocean-derived materials are present at Europa’s surface, they would represent accessible records of ocean chemistry and habitability, but such materials would be further processed by the moon’s harsh radiation environment. In this study, saturated fatty acids were precipitated onto a Europa-relevant hydrated magnesium sulfate and exposed to gamma radiation doses up to 2 MGy at -196° C. Alkane chains, with carbon numbers one less than those of the starting fatty acids, were the most abundant radiolysis products in solvent and thermal extracts analyzed by gas chromatography mass spectrometry. Detections of monounsaturated fatty acids and combined radiolysis products were attributed to the experiment’s Europa-like parameters. Additionally, elevated concentrations of shorter-chain saturated fatty acids suggest that gamma radiation induced charge remote fragmentation of the alkyl chains of some starting fatty acids under these experimental conditions. Quantitation of fatty acid concentrations in the irradiated samples enabled the calculation of a radiolysis constant that indicated exposure to a 5 MGy dose of gamma radiation would have resulted in a ~90% loss of the initial fatty acid population. The samples were further studied by Raman spectroscopy and laser desorption and ionization mass spectrometry, which characterized the distribution of fatty acids and their radiolysis products on sulfate surfaces. The substantial loss of starting fatty acids typically seen with increasing radiation dose, along with the remarkable diversity of radiolysis products identified, suggest that the detection of fatty acids in irradiated sulfate deposits on Europa will be challenged by rapid destruction of any initial fatty acid populations and scrambling of their residual signals by a myriad of organic radiolysis products. If missions to Europa encounter sulfate deposits, targeting minimally irradiated units may still enable the detection of surviving fatty acid signatures that could inform about Europa’s subsurface chemistry and habitability.

James M T Lewis↗

NASA NTRS2024

Exploration Systems Exterior Lighting Design Guidance

Humans are returning to the Moon — this time, to stay. NASA has selected a location that maximizes line-of-sight communication with Earth, solar visibility, and access to water ice: the Lunar South Pole (LSP). While the Sun is more consistently in the lunar sky at the poles, it never rises more than 7° above the horizon in the target landing regions. This harsh lighting environment--never experienced during the Apollo missions or in human spaceflight--presents an engineering challenge: Support and protect functional vision. The human vision system, which despite having a high-dynamic range, cannot see well into bright light and cannot adapt quickly from bright to dark or vice versa. The design of helmets, windows, and lighting solutions must work in a complementary fashion to achieve a system of lighting and functional vision support that enables crews to see into darkness while their eyes are light-adapted and see in bright light while still dark-adapted that protects their eyes from injury. This report brings together information and identifies gaps related to LSP Natural environment (topology, regolith, temperature, lighting, and so forth), NASA historical experience exploring the Moon, human vision capabilities and needs, exploration operations, simulation capabilities and needs (for design verification, training, mission planning, and so forth) and existing engineering, safety, medical and performance requirements related to support human exploration.

Simulation↗

NASA NTRSDate not supplied

Abrasive Effects of Lunar Regolith on Material Wear for Long-Term Lunar Applications

Long-term operations on the Moon’s surface require materials that can withstand the harsh lunar environment. Lunar dust and regolith pose significant threats to the long-term durability of materials used in lunar applications. Lunar dust, easily perturbed and dispersed, adheres and abrades materials due to its rough and irregular grain morphology. More closely representing this abrasion action through experimental laboratory testing is critical in assessing the durability of potential lunar candidate materials used in mechanical, sensor, and human-based systems. In this study, the performance of materials using Taber abrasive wheels made from lunar regolith simulant was assessed and compared to results obtained using standard ceramic-based abrasion materials. The results highlight a difference in the abrasive wear rates between the lunar regolith simulant and the standard ceramic-based abrasive. Utilizing the mechanisms and testing capabilities of this two-body abrasive interaction leveraging regolith-based abrasives may more closely represent the interplay between materials and lunar dust, which is vital for assessing the long-term viability of materials for extended lunar missions. Improved lunar testing capabilities may also enhance evaluations of the long-term performance degradation of passive and active dust mitigation methods.

Zachary Stein↗

NASA NTRSDate not supplied

Design of an AI Trash Sorting Machine for Use on the Moon and Mars

As NASA prepares for Mars colonization, resource conservation will be critical for survival. Artificial Intelligence (AI) powered waste sorting technologies, already emerging on Earth, offer promising solutions for recycling and material recovery. These systems use advanced sensors and machine learning algorithms to identify and separate materials with remarkable accuracy. On Mars, where every item has significant value, efficient recycling will be essential to reduce resupply needs and support closed-loop life support systems. This paper explores how terrestrial AI-based trash sorting technologies can be adapted for Martian conditions, focusing on challenges such as the harsh surface environment, minimizing system mass, power, volume, and estimating waste composition. Addressing these issues will be key to enabling sustainable operations on the Red Planet.

Sorting↗

NASA NTRSDate not supplied

Design of an AI Trash Sorting Machine for Use on the Moon and Mars

AI↗

DOE OSTI2020

Study of Additive Manufacturing Application to Geothermal Technologies

Geothermal reservoir characterization, field construction, and reservoir operations are very technology intensive activities that contribute significantly to the cost of delivering electricity produced from geothermal resources. Many geothermal technologies, such as downhole tools and drilling equipment, have unusual material, design, and manufacturing considerations dictated by the harsh geothermal environment and extreme aspect ratios required for deployment in a borehole. An additional challenge that faces geothermal applications is the low tool production volume needed to support the industry. Whereas tens of thousands of Oil & Gas wells are drilled and completed in the U.S. annually, there are typically only tens of geothermal wells that are drilled and completed. If a tool typically used in Oil & Gas applications cannot be directly used for geothermal, then the cost associated with making the tool suitable for geothermal is often prohibitive. There is therefore a much smaller inventory of technologies available to geothermal as compared to Oil & Gas and the level of efficiency and sophistication associated with field practice suffers accordingly. A number of advanced manufacturing methods, such as additive manufacturing, have received increased R&D as well as commercial attention in recent years because of their ability to rapidly prototype complex parts. Additive manufacturing in particular provides an opportunity to increase the technology available to the geothermal industry by either reducing fabrication costs associated with complex components or enabling economic production of low volume parts where specialized tooling is often required. Additional potential benefits of additive manufacturing include increased design freedom to make higher performing parts that cannot be made conventionally, the ability to integrate components into assemblies without joining operations, and the ability to economically fabricate variations on design in cases, such as casting molds, where there are large up-front costs associated with tooling. We have recently completed a study that investigated technology needs, representative use cases, manufacturability, and a techno-economic framework for comparing conventional to additive manufacturing methods for geothermal applications. This paper will provide an overview of this recent effort, describe the different elements of the assessment, and summarize the key takeaways related to both the feasibility of using additive manufacturing for geothermal technology applications as well as the potential benefits and impacts.

Polsky, Yarom↗

DOE OSTI2021

Development of Bismuth and Platinum Bi-Metallic Nanoparticles to Enhance Melt Wire Temperature Resolution

Advanced manufacturing (AM) based on direct-write (DW) technologies has emerged as the predominant enabler for the fabrication of active and passive sensors to be deployed in harsh operating environments seen in a nuclear reactor. Recently, Idaho National Laboratory and Boise State University have recently established capabilities to incorporate advanced manufacturing (AM) methods to accelerate, modernize and enhance functionality of nuclear sensors and instrumentation to achieve the goal of enhancing the safety and efficiency of nuclear reactors. A significant thrust of this work includes the development of nuclear relevant feedstock materials compatible with a variety of direct-write processes for the development, fabrication and testing of AM sensors for peak temperature detection and neutron flux monitoring. For this report, bismuth and bismuth/platinum (BiPt) bi-metallic nanoparticles were synthesized using wet chemical approaches to develop bi-metallic feedstock materials to enhance the sensitivity of melt wires for peak temperature detection. Nanoparticle characterization was performed with Transmission Electron Microscopy (TEM) for nanoparticle composition and size, Transmission X-Ray Diffraction Fluorescence (TXRF) for nanoparticle composition, and Differential Scanning Calorimetry to elucidate the melting point of BiPt bi-metallic nanoparticles. Preliminary results indicate bi-metallic BiPt nanoparticles as a viable pathway for fabricating high resolution AM melt wires.

36 MATERIALS SCIENCE↗