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NASA NTRS2019

Small Stirling Technology Exploration Power for Future Space Science Missions

High efficiency dynamic Radioisotope Power Systems (RPS) could be mission enabling for low power space applications such as small probes, landers rovers, and communication repeaters. These applications would contain science instruments and be distributed across planetary surfaces or near objects of interest where solar flux is insufficient for using solar cells. Small RPS could be used to provide power for sensing radiation, temperature, pressure, seismic activity, and other measurements of interest to planetary scientists. Small RPS would use fractional versions of the General Purpose Heat Source (GPHS) or Light Weight Radioisotope Heater Units (LWRHU), to heat power conversion technologies. Dynamic power systems are capable of three to four times higher conversion efficiency compared to static power conversion technologies, and would provide an equal amount of power using less fuel or more power using an equal amount of fuel. Providing spacecraft with more power could decrease duty cycling of basic functions and, therefore, increase the quality and abundance of science data. NASA Glenn Research Center (GRC) is developing a low power dynamic RPS that would convert heat from multiple LWRHU to one watt of usable direct current electric power for spacecraft instrumentation and communication. The power system could be used to charge batteries or capacitors for higher power burst usage. The initial design, called Small Stirling Technology Exploration Power (smallSTEP), is around 3 kg, 11 cm diameter X 32 cm long, and converts 8 watts of heat to one watt of electricity using a Stirling convertor. This low power conversion system represents a new class of RPS with power levels two orders of magnitude lower than prototypes currently being developed for space applications under NASA contracts. Development of the 1-watt RPS includes maturation of convertor and controller designs, performance evaluation of an evacuated metal foil insulation, and development of system interfaces. Initial demonstration of the subsystems has been completed in a laboratory environment and a higher fidelity system is being pursued for demonstration in relevant environments for use on small spacecraft needed to carry out future space science missions.

Wilson, Scott↗
NASA NTRS2019

Overview of Multi-Layer Metal Insulation Development for Small Stirling Convertors at NASA GRC

The small Stirling convertor currently under development at the NASA Glenn Research Center (GRC) is designed to produce one watt of electrical power from eight watts of heat. Previous radioisotope power systems (RPS) made use of the General-Purpose Heat Source (GPHS) which produces 250 watts of heat but is unsuitable for a one-watt Stirling convertor. The only heat source available is the Light-Weight Radioisotope Heating Unit (LWRHU) which produces one watt of heat and is primarily used to provide heat to electronics and instrumentation to maintain their appropriate operating temperature. Unfortunately, the LWRHU has a heat flux of 272 W/m-squared compared to the GPHS heat flux of 6000 W/m-squared which greatly increases the demands on the insulation to ensure that enough of the heat produced is available to the convertor and not lost to the environment. An analysis was performed that showed that the insulation must have a thermal conductivity of 0.005 W/m·K or better for the system to function. A multi-layer metal insulation package was designed and a prototype was fabricated and tested to investigate the feasibility of this design. The prototype did not meet the requirements; however, the improved thermal model generated using the test data will allow for a second iteration to be developed that has a much higher confidence and meets the performance requirements.

Goodell, Daniel D.↗
NASA NTRS2019

NASA Proof-of-Concept 1-W Stirling Convertor Development for Small RPS

Low power Stirling convertors are being developed at NASA Glenn Research Center (GRC) to provide future small spacecraft with electrical power by converting heat from one or more Light Weight Radioisotope Heater Units (LWRHU). An initial design converts multiple watts of heat to one watt of electrical power output using a Stirling convertor. A variety of mission concepts have been studied by NASA and the U. S. Department of Energy (DOE) that would utilize low power Radioisotope Power Systems (RPS) for probes, landers, rovers, and repeaters. These missions would contain science instruments distributed across planetary surfaces or near objects of interest where solar flux is insufficient for using solar cells. Landers could be used to provide data such as, radiation, temperature, pressure, seismic activity, and other surface measurements for planetary science and to inform future mission planners. The studies propose using fractional versions of the General Purpose Heat Source (GPHS) or multiple LWRHUs to heat power conversion technologies for science instruments and communication. Dynamic power systems are capable of higher conversion efficiencies, which could enable equal power using less fuel or more power using equal fuel, when compared to less efficient static power conversion technologies. Providing spacecraft with more power would decrease duty cycling of basic functions and, therefore, increase the quality and abundance of science data. Efforts to develop the concept have focused on maturation of a 1-We convertor and controller design and performance evaluation of an evacuated metal foil insulation. A proof-of-concept 1-We convertor, controller, and evacuated metal foil insulation package have been fabricated and are undergoing characterization testing. The current status, findings, and path forward for the effort are explained in this paper.

Schifer, Nicholas A.↗
NASA NTRS2019

NASA Proof-of-Concept 1-W Stirling Convertor Development for Small RPS

Low power Stirling convertors are being developed at NASA Glenn Research Center (GRC) to provide future small spacecraft with electrical power by converting heat from one or more Light Weight Radioisotope Heater Units (LWRHU). An initial design converts multiple watts of heat to one watt of electrical power output using a Stirling convertor. A variety of mission concepts have been studied by NASA and the U.S. Department of Energy (DOE) that would utilize low power Radioisotope Power Systems (RPS) for probes, landers, rovers, and repeaters. These missions would contain science instruments distributed across planetary surfaces or near objects of interest where solar flux is insufficient for using solar cells. Landers could be used to provide data such as, radiation, temperature, pressure, seismic activity, and other surface measurements for planetary science and to inform future mission planners. The studies propose using fractional versions of the General Purpose Heat Source (GPHS) or multiple LWRHUs to heat power conversion technologies for science instruments and communication. Dynamic power systems are capable of higher conversion efficiencies, which could enable equal power using less fuel or more power using equal fuel, when compared to less efficient static power conversion technologies. Providing spacecraft with more power would decrease duty cycling of basic functions and, therefore, increase the quality and abundance of science data. Efforts to develop the concept have focused on maturation of a 1-We (1-watt electrical) convertor and controller design and performance evaluation of an evacuated metal foil insulation. A proof-of-concept 1-We convertor, controller, and evacuated metal foil insulation package have been fabricated and are undergoing characterization testing. The current status, findings, and path forward for the effort are explained in this paper.

Stirling↗
NASA NTRS2019

Overview of Multi-Layer Metal Insulation Development for Small Stirling Convertors at NASA GRC

The small Stirling convertor currently under development at the NASA Glenn Research Center (GRC) is designed to produce one watt of electrical power from eight watts of heat. Previous radioisotope power systems (RPS) made use of the General-Purpose Heat Source (GPHS) which produces 250 watts of heat but is unsuitable for a one-watt Stirling convertor. The only heat source available is the Light-Weight Radioisotope Heating Unit (LWRHU) which produces one watt of heat and is primarily used to provide heat to electronics and instrumentation to maintain their appropriate operating temperature. Unfortunately, the LWRHU has a heat flux of 272 W/m-squared (watts per square meter) compared to the GPHS heat flux of 6000 W/m-squared which greatly increases the demands on the insulation to ensure that enough of the heat produced is available to the convertor and not lost to the environment. An analysis was performed that showed that the insulation must have a thermal conductivity of 0.005 W/m squared -K (watts per square meter per Kelvin) or better for the system to function. A multi-layer metal insulation package was designed and a prototype was fabricated and tested to investigate the feasibility of this design. The prototype did not meet the requirements; however, the improved thermal model generated using the test data will allow for a second iteration to be developed that has a much higher confidence and meets the performance requirements.

Goodell, Daniel↗
NASA NTRS2019

NASA Proof-of-Concept 1-W(sub e) Stirling Convertor Development for Small Radioisotope Power Systems

Low power Stirling convertors are being developed at NASA Glenn Research Center to provide future small spacecraft with electrical power by converting heat from one or more Light Weight Radioisotope Heater Units (LWRHU). An initial design converts multiple watts of heat to one watt of electrical power output using a Stirling convertor. A variety of mission concepts have been studied by NASA and the U. S. Department of Energy that would utilize low power Radioisotope Power Systems (RPS) for probes, landers, rovers, and repeaters. These missions would contain science instruments distributed across planetary surfaces or near objects of interest where solar flux is insufficient for using solar cells. Landers could be used to provide data such as, radiation, temperature, pressure, seismic activity, and other surface measurements for planetary science and to inform future mission planners. The studies propose using fractional versions of the General Purpose Heat Source or multiple LWRHUs to heat power conversion technologies for science instruments and communication. Dynamic power systems are capable of higher conversion efficiencies, which could enable equal power using less fuel or more power using equal fuel, when compared to less efficient static power conversion technologies. Providing spacecraft with more power would decrease duty cycling of basic functions and, therefore, increase the quality and abundance of science data. Efforts to develop the concept have focused on maturation of a 1-We convertor and controller design and performance evaluation of an evacuated metal foil insulation. A proof-of-concept 1-We convertor, controller, and evacuated metal foil insulation package have been fabricated and are undergoing characterization testing. The current status, findings, and path forward for the effort are explained in this paper.

Schifer, Nicholas A.↗
NASA NTRS2020

Overview of MultiLayer Metal Insulation Development for Small Stirling Convertors at NASA Glenn Research Center

A small Stirling convertor is currently under development at the NASA Glenn Research Center to produce one watt of electrical power from eight watts of heat. Previous radioisotope power systems made use of the General-Purpose Heat Source (GPHS) which produces 250 watts of heat but is unsuitable for a one-watt Stirling convertor. The only other qualified heat source available is the Light-Weight Radioisotope Heating Unit (LWRHU), which produces one watt of heat and is primarily used to provide heat to electronics and instrumentation to maintain their appropriate operating temperature. Unfortunately, the LWRHU has a heat flux of 272 W/meters squared compared to the GPHS heat flux of 6000 W/m2 which greatly increases the demands on the insulation to ensure that enough of the heat produced is available to the convertor and not lost to the environment. An analysis was performed that showed that the insulation must have an effective thermal conductivity of 0.005 W/m·K or better for the system to function. A multi-layer metal insulation package was designed and a prototype was fabricated and tested to investigate the feasibility of this design. While the prototype did not meet the requirements perfectly, the lessons learned are being used to generate an improved thermal model using the test data so that a second iteration can developed that will meet the performance requirements with a much higher confidence.

Daniel D Goodell↗
NASA NTRS2021

The Case for a 50+ Year Radioisotope Power System

The Johns Hopkins University Applied Physics Laboratory (JHU/APL) is leading the NASA funded Interstellar Probe study to explore the “Very Local” interstellar medium. To perform this exploration the mission will be required to last at least 50 years in regions of space where solar power is no longer practical. Additionally, several new studies for the National Academies’ Planetary Science and Astrobiology Decadal Survey are planning missions lasting 20-35 years. The Decadal Survey is used to build consensus on priority of national science goals. These proposed missions are inconsistent with the NASA’s current Radioisotope Power Systems (RPS) life requirement of 14 years (flight). Paramount to these proposed long-duration missions are questions about the longevity of such a mission. Evidence exists that space-borne Radioisotope Power Systems can indeed last a long time. LES-9, Voyager I, and Voyager II are over 40 years old, LES-8, Pioneer 10, and Pioneer 11 lasted 28, 30, and 22 years, respectively, and New Horizons is still active 15 years after launch. This paper explores the need for RPS designs that are intended to last much longer than the current requirement of 14 years (17 years after fueling) and explores the historical record for actual vs design lifetimes to show the feasibility of building long lasting RPS. We also exercise a current RTG performance model of the General-Purpose Heat Source RTG using the JPL Lifetime Performance Prediction (LPP) tool to make top-level inferences about power output at end-of-mission, and discusses how reliability engineering and testing methods can be brought to bear to increase confidence in delivering sufficient power at end-of-mission.

Phan, Brian↗
NASA NTRS2022

Dynamic Radioisotope Power System (DRPS) Design Reference Mission (DRM) Lunar Rover

The Radioisotope Power Systems (RPS) Program tasked the Compass Team to evaluate use of Dynamic Radioisotope Power Systems (DRPS) for lunar science rovers. The object was to identify their advantages and challenges as well as to influence the technology developments with flight-type requirements. This was easily done by using the promising Volatiles Investigating Polar Exploration Rover (VIPER) solar- powered rover mission as a platform to ‘swap in’ a DRPS. The ‘pickup truck bed’ approach allowed both simplified installation and operation of the DRPS while keeping the forward lunar surface ‘blocked’ from the DRPS waste heat which could sublimate the icy surface. It was found that with the Stirling DRPS option the mass is within the planned VIPER lander capability and is very close to VIPER mass and size (the DRPS replaces large battery pack/solar arrays). The Stirling DRPS option produced ~300 Watts electrical (We) using six general purpose heat source (GPHS) bricks and eight Stirling convertors. Replacing the solar/battery power with radioisotope power allows a continuous presence (instead of 6 hours) in a permanently shadowed region (PSR) and over 18 months of operations with minimal science impact (rearward surface heating). It was also found that use of a dynamic system (instead of a thermoelectric system) reduces the heat impact on the science environment two-to-three times. The DRPS, along with a relay link (like Gateway), can provide continuous access to PSRs. The system was also found to be capable of roving for 8 hours per day with a range of over 500 km in 18 months. Preliminary cost estimates fit into a Class D mission but only assuming VIPER heritage and launch, lander, operations, nuclear specific costs [National Environmental Policy Act (NEPA), fueling, transport, Launch Services Program (LSP), etc.] and DRPS are not included.

DRPS↗
NASA NTRSDate not supplied

The Next Generation Radioisotope Thermoelectric Generator Project - Overview and Progress Status

The Next Generation Radioisotope Thermoelectric Generator (Next Gen RTG) Project is a spaceflight system project within NASA’s Radioisotope Power Systems (RPS) Program. The project, in partnership with the Idaho National Laboratory (INL) / Battelle Energy Alliance (BEA), will build and deliver an unfueled, flight qualified Radioisotope Thermoelectric Generator (RTG) system based on RPS Program needs. The Next Gen RTG Project aims to assure the availability of high-power, vacuum-rated RTGs to enable future deep space missions. The Project team is developing that capability through a multi-phase effort that leverages the heritage General Purpose Heat Source - RTG (GPHS-RTG) design and available legacy hardware. The Project’s primary aim is to re-establish the capability to manufacture a silicon germanium (SiGe) unicouple based thermoelectric converter and associated hardware with minimal changes to the heritage GPHS-RTG design. The project will also refurbish the GPHS-RTG Flight Unit #5 (F-5) located at INL and verify its compliance with heritage GPHS-RTG requirements. This paper will detail the project’s plans for the development of these systems. Management approaches, technical challenges, and risks will also be discussed.

Radioisotope↗
NASA NTRS2022

MSL MMRTG Power Modeling for Lifetime Performance Predictions

The Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) has been providing power to the Mars Science Laboratory (MSL) rover, Curiosity, for surface operations since 2012. The Jet Propulsion Laboratory (JPL) has employed the Life Performance Prediction Model (LPPM) to generate predictions and outputs based upon flight data from the rover and experimental data from the thermoelectric (TE) couples. In order to make these predictions, LPPM requires various spacecraft inputs relevant to RTG performance such as fin root temperature, load voltage, general purpose heat source (GPHS) inventory, etc., combined with couple data such as thermoelectric properties, interface degradation, and sublimation properties. With tens of thousands of hours of flight data to date, LPPM can not only track performance to date, but also make predictions on the power output of the MMRTG through the 17-year end-of-design-life (EODL). These predictions are useful for mission planners and surface operators who rely on the MMRTG for power in order to perform the critical science necessary during the mission. This paper will showcase the power data extracted from the flight electronics, comparing it to the predictions and outputs generated from LPPM.

Pinkowski, Stanley↗
NASA NTRS1988

Radioisotope powered alkali metal thermoelectric converter design for space systems

The design concept of an alkali-metal thermoelectric converter (AMTEC) for 15-30-percent-efficient conversion of heat from the General Purpose (radioisotope) Heat Source (GPHS) on spacecraft is presented. The basic physical principles of the conversion cycle are outlined; a theoretical model is derived; a modular design is described and illustrated with drawings; and the overall AMTEC/GPHS system design is characterized. Predicted performance data are presented in extensive tables and graphs and discussed in detail.

Sievers, R. K.↗
NASA NTRS1990

Galileo spacecraft power management and distribution system

The Galileo PMAD (power management and distribution system) is described, and the design drivers that established the final as-built hardware are discussed. The spacecraft is powered by two general-purpose heat-source-radioisotope thermoelectric generators. Power bus regulation is provided by a shunt regulator. Galileo PMAD distributes a 570-W beginning of mission (BOM) power source to a user complement of some 137 load elements. Extensive use of pyrotechnics requires two pyro switching subassemblies. They initiate 148 squibs which operate the 47 pyro devices on the spacecraft. Detection and correction of faults in the Galileo PMAD is an autonomous feature dictated by requirements for long life and reliability in the absence of ground-based support. Volatile computer memories in the spacecraft command and data system and attitude control system require a continuous source of backup power during all anticipated power bus fault scenarios. Power for the Jupiter Probe is conditioned, isolated, and controlled by a Probe interface subassembly. Flight performance of the spacecraft and the PMAD has been successful to date, with no major anomalies.

Detwiler, R. C.↗
NASA NTRS1991

Risk analysis of an RTG on the Space Shuttle

As part of the effort to review the Ulysses Final Safety Analysis Report and to understand the risk of plutonium release from the Ulysses spacecraft General Purpose Heat Source-Radioisotope Thermal Generator (GPHS-RTG), the Interagency Nuclear Safety Review Panel (INSRP) and the author performed an integrated, quantitative analysis of the uncertainties of the calculated risk of plutonium release from Ulysses. Using state-of-the-art probabilistic risk assessment technology, the uncertainty analysis accounted for both variability and uncertainty of the key parameters of the risk analysis. The results show tht INSRP had high confidence that risk of fatal cancers from potential plutonium release associated with calculated launch and deployment accident scenarios is low.

Frank, Michael V.↗
NASA NTRS1991

Uncertainty analysis for Ulysses safety evaluation report

As part of the effort to review the Ulysses Final Safety Analysis Report and to understand the risk of plutonium release from the Ulysses spacecraft General Purpose Heat Source-Radioisotope Thermal Generator, the Interagency Nuclear Safety Review Panel (INSRP) performed an integrated, quantitative analysis of the uncertainties of the calculated risk of plutonium release from Ulysses. Using state-of-art probabilistic risk assessment technology, the uncertainty analysis accounted for both variability and uncertainty of the key parameters of the risk analysis. The results show that INSRP had high confidence that risk of fatal cancers from potential plutonium release associated with calculated launch and deployment accident scenarios is low.

Frank, Michael V.↗
NASA NTRS2017

Next-Generation RTGs for NASA

NASA has used Radioisotope Thermoelectric Generators (RTGs) for nearly five decades to power planetary science missions where solar arrays or other power systems were impractical or ineffective. The Multi-Mission RTG (MMRTG) is the only type of RTG available for spaceflight today and it relies on technology used for the Pioneer and Viking missions of the 1970s. The MMRTG’s distant-relative, the General-Purpose Heat Source-RTG (GPHS-RTG), went out of production shortly after the turn of the twenty-first century. The thermoelectric technology it relied upon is several decades old and was first flown on the Voyager missions in 1977. While the GPHS-RTG could theoretically be brought out of mothballs, many advances have been made in thermoelectric materials, advances that warranted a clear-eyed review and study of the optimal properties of a “next-generation” RTG. This paper summarily describes the outcome of the study.

Woerner, David F.↗
NASA NTRS2001

High efficiency segmented thermoelectric unicouples

Highly efficient, segmented thermoelectric unicouple incorporating advanced thermoelectric materials with superior thermoelectric figures of merit are currently being developed at the Jet Propulsion Laboratory (JPL).

segmented↗