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DOE OSTI2018

Data from Increasing Ethanol Yield through Fiber Conversion in Corn Dry Grind Process

Conversion of corn fiber to ethanol in the dry grind process could increase ethanol yields, reduce downstream processing costs and improve overall process profitability. This work investigates the in-situ conversion of corn fiber into ethanol (cellulase addition during simultaneous saccharification and fermentation) during dry grind process. Addition of 30 FPU/g fiber cellulase resulted in 4.6% increase in ethanol yield compared to the conventional process. Use of excess cellulase (120 FPU/g fiber) resulted in incomplete fermentation and lower ethanol yield compared to the conventional process. Multiple factors including high concentrations of ethanol and phenolic compounds were responsible for yeast stress and incomplete fermentation in excess cellulase experiments.

Conversion↗

NASA NTRS2011

Method to Estimate the Dissolved Air Content in Hydraulic Fluid

In order to verify the air content in hydraulic fluid, an instrument was needed to measure the dissolved air content before the fluid was loaded into the system. The instrument also needed to measure the dissolved air content in situ and in real time during the de-aeration process. The current methods used to measure the dissolved air content require the fluid to be drawn from the hydraulic system, and additional offline laboratory processing time is involved. During laboratory processing, there is a potential for contamination to occur, especially when subsaturated fluid is to be analyzed. A new method measures the amount of dissolved air in hydraulic fluid through the use of a dissolved oxygen meter. The device measures the dissolved air content through an in situ, real-time process that requires no additional offline laboratory processing time. The method utilizes an instrument that measures the partial pressure of oxygen in the hydraulic fluid. By using a standardized calculation procedure that relates the oxygen partial pressure to the volume of dissolved air in solution, the dissolved air content is estimated. The technique employs luminescent quenching technology to determine the partial pressure of oxygen in the hydraulic fluid. An estimated Henry s law coefficient for oxygen and nitrogen in hydraulic fluid is calculated using a standard method to estimate the solubility of gases in lubricants. The amount of dissolved oxygen in the hydraulic fluid is estimated using the Henry s solubility coefficient and the measured partial pressure of oxygen in solution. The amount of dissolved nitrogen that is in solution is estimated by assuming that the ratio of dissolved nitrogen to dissolved oxygen is equal to the ratio of the gas solubility of nitrogen to oxygen at atmospheric pressure and temperature. The technique was performed at atmospheric pressure and room temperature. The technique could be theoretically carried out at higher pressures and elevated temperatures.

Hauser, Daniel M.↗

DOE OSTI2016

Development of a CO 2 Chemical Sensor for Downhole CO 2 Monitoring in Carbon Sequestration

Geologic storage of carbon dioxide (CO 2 ) has been proposed as a viable means for reducing anthropogenic CO 2 emissions. The means for geological sequestration of CO 2 is injection of supercritical CO 2 underground, which requires the CO 2 to remain either supercritical, or in solution in the water/brine present in the underground formation. However, there are aspects of geologic sequestration that need further study, particularly in regards to safety. To date, none of the geologic sequestration locations have been tested for storage integrity under the changing stress conditions that apply to the sequestration of very large amounts of CO 2 . Establishing environmental safety and addressing public concerns require widespread monitoring of the process in the deep subsurface. In addition, studies of subsurface carbon sequestration such as flow simulations, models of underground reactions and transports require a comprehensive monitoring process to accurately characterize and understand the storage process. Real-time information about underground CO 2 movement and concentration change is highly helpful for: (1) better understanding the uncertainties present in CO 2 geologic storage; (2) improvement of simulation models; and (3) evaluation of the feasibility of geologic CO 2 storage. Current methods to monitor underground CO 2 storage include seismic, geoelectric, isotope and tracer methods, and fluid sampling analysis. However, these methods commonly resulted low resolution, high cost, and the inability to monitor continuously over the long time scales of the CO 2 storage process. A preferred way of monitoring in-situ underground CO 2 migration is to continuous measure CO 2 concentration change in brine during the carbon storage process. An approach to obtain the real time information on CO 2 concentration change in formation solution is highly demanded in carbon storage to understand the CO 2 migration subsurface and to answer the public safety problem. The objective of the study is to develop a downhole CO 2 sensor that can in-situ, continuously monitor CO 2 concentration change in deep saline. The sensor is a Severinghaus-type CO 2 sensor with small size, which renders it can be embedded in monitoring well casing or integrated with pressure/temperature transducers, enabling the development of “smart” wells. The studies included: (1) prepare and characterize metal-oxide electrodes. Test the electrodes response to pH change. Investigate different ions and brine concentration effects on the electrode’s performance. Study the stability of the electrode in brine solution; (2) fabricate a downhole CO 2 sensor with the metal-oxide electrodes prepared in the laboratory. Test the performance of the CO 2 sensor in brine solutions. Study high pressure effects on the performance of the sensor; (3) design and conduct CO 2 /brine coreflooding experiments with the CO2 sensor. Monitor CO 2 movement along the core and test the performance of the sensor in coreflooding tests. Develop a data acquisition system that can digitize the sensor’s output voltage. Our completed research has resulted in deep understanding of downhole CO 2 sensor development and CO 2 monitoring in CO 2 storage process. The developed downhole CO 2 sensor included a metal-oxide electrode, a gas-permeable membrane, a porous steel cup, and a bicarbonate-based internal electrolyte solution. Iridium oxide-based electrode was prepared and used for preparation the CO 2 sensor. The prepared iridium oxide-based electrode displayed a linearly response to pH change. Different factors such as different ions and ions concentration, temperature, and pressure effects on the electrode performance on pH response were investigated. The results indicated that the electrode exhibited a good performance even in high salt concentration of produced water. To improve the electrode performance under high pressure, IrO 2 nanoparticles with the particle size in the range of 1-2 nm were prepared and electrodeposited on stainless steel substrate by cyclic voltammetry. It was observed that the thin film of iridium oxide was formed on the substrate surface and such iridium oxide-based electrode displayed excellent performance under high pressure for longer term. A downhole CO 2 sensor with the iridium oxide-based electrode was prepared. The working principle of the CO 2 sensor is based on the measurement of the pH change of the internal electrolyte solution caused by the hydrolysis of CO 2 and then determination of the CO 2 concentration in water. The prepared downhole CO 2 sensor had the size of diameter of 0.7 in. and length of 1.5 in. The sensor was tested under the pressures of 500 psi, 2,000 psi, and 3,000 psi. A linear correlation was observed between the sensor potential change and dissolved CO 2 concentration in water. The response time of the CO 2 sensor was in the range of 60-100 minutes. Further tests indicated that the CO 2 sensor exhibited good reproducibility under high pressure. A CO 2 /brine coreflooding system was constructed to simulate the real-world CO 2 storage process. The prepared downhole CO 2 sensor was loaded in the system to monitor CO 2 movement during CO 2 /brine coreflooding test. The results indicated that the sensor could detect CO 2 movement in the tests. Further studies showed that the sensor could be recovered by brine flooding after CO 2 /brine flushed the core. The results of the coreflooding tests demonstrated that the sensor had potential application for CO 2 monitoring in carbon sequestration. A data acquisition system for the downhoe CO 2 sensor was developed and coded. The system converted the sensor output signal into digital data and transported the data from downhole to wellhead surface. The data acquisition system was tested and evaluated in the laboratory with the prepared sensor for data collection.

36 MATERIALS SCIENCE↗

NASA NTRS2004

Recent Advances in Synthesis and Characterization of SWCNTs Produced by Laser Oven Process

Results from the parametric study of the two-laser oven process indicated possible improvements with flow conditions and laser characteristics. Higher flow rates, lower operating pressures coupled with changes in flow tube material are found to improve the nanotube yields. The collected nanotube material is analyzed using a combination of characterization techniques including SEM, TEM, TGA, Raman and UV-VIS-NIR to estimate the purity of the samples. In-situ diagnostics of the laser oven process is now extended to include the surface temperature of the target material. Spectral emission from the target surface is compared with black body type emission to estimate the temperature. The surface temperature seemed to correlate well with the ablation rate as well as the quality of the SWCNTs. Recent changes in improving the production rate by rastering the target and using cw laser will be presented.

Aepalli, Sivaram↗

DOE OSTI2016

Atomistic Conversion Reaction Mechanism of WO 3 in Secondary Ion Batteries of Li, Na, and Ca

Abstract Intercalation and conversion are two fundamental chemical processes for battery materials in response to ion insertion. The interplay between these two chemical processes has never been directly seen and understood at atomic scale. Here, using in situ HRTEM, we captured the atomistic conversion reaction processes during Li, Na, Ca insertion into a WO 3 single crystal model electrode. An intercalation step prior to conversion is explicitly revealed at atomic scale for the first time for Li, Na, Ca. Nanoscale diffraction and ab initio molecular dynamic simulations revealed that after intercalation, the inserted ion–oxygen bond formation destabilizes the transition‐metal framework which gradually shrinks, distorts and finally collapses to an amorphous W and M x O (M=Li, Na, Ca) composite structure. This study provides a full atomistic picture of the transition from intercalation to conversion, which is of essential importance for both secondary ion batteries and electrochromic devices.

He, Yang↗

DOE OSTI2015

SHMTools: Structural Health Monitoring Software for Aerospace, Civil, and Mechanical Infrastructure

Structural Health Monitoring (SHM) involves a multitude of processes designed to detect damage in situ on various types of structures, from aircraft and buildings to bridges and mechanical infrastructure. In an early example of SHM, railroad wheeltappers used a hammer to strike train wheels to determine if there was damage present. At Los Alamos, scientists have developed SHMTools, a software suite that provides more than 100 advanced algorithms that quickly prototype and evaluate damage-detection processes. The software consists of modular MATLAB routines covering the three main stages of SHM: data acquisition, feature extraction, and feature classification. Multiple sensing modalities are supported, including acceleration, strain, and guided-wave data, all of which have been widely used in SHM practice.

42 ENGINEERING↗

NASA NTRSDate not supplied

Experimental Observations of Mechanisms of Pattern Formation During Freeze Casting

Empirically, many different materials compositions have been freeze cast over the years. Few have been analyzed to better understand the mechanisms by which the ice crystal growth drives structure formation, particularly the substructures on the cell walls. Collating substructural features, for example, ridges, bridges, and “jellyfish-like” substructures, found on the cell walls of freeze-cast ceramics (platelets versus particles), fibrillated biopolymers (collagen, nanocellulose), and "smooth" biopolymers (chitosan, trehalose), we capture the ice crystal growth process and analyze it both in situ in 2D and "post-mortem" in 3D to gain insights into anisotropic ice crystal growth and other self-assembly mechanisms. Combining these experimental observations with 3D Phase-field simulations of structure formation in ice-templated materials, detailed in a companion presentation, it becomes possible to gain fundamental science insights and to obtain the desired structure-property-processing correlations not only at the more traditional macroscopic, but also at the meso- and microscopic scales.

Kaiyang Yin↗

NASA NTRSDate not supplied

Experimental Observations of Mechanisms of Pattern Formation During Freeze Casting

Kaiyan Yin↗

DOE OSTI2019

Research on Phase Reaction of Nb{sub 3}Al Precursor During Rapid Heating Process

Short samples of Nb{sub 3}Al precursor are heated by Ohm heating. The curves of temperature vs heating time are investigated to study the phase reaction of jelly-roll precursor and in situ powder-in-tube precursor during the rapid heating process. A short constant temperature process occurs at about 2000 {sup ∘}C. It is proved that the reaction that generates body-centered cubic (BCC) solid solution phase is reversible. For jelly-roll precursor, metallographic images show that no reaction occurs between Nb/Al roll and Nb matrix. Voids and cracks become larger as the precursor is processed for multiple times. For in situ powder-in-tube precursor, Nb and Al powder is not reacted completely. Using smaller original Nb powder and Al powder is good for the formation of BCC solid solution.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Emergence of Rapid Oxygen Surface Exchange Kinetics during in Situ Crystallization of Mixed Conducting Thin Film Oxides

The oxygen surface exchange kinetics of mixed ionic and electronic conducting oxides (MIECs) play a vital role in the efficiency of intermediate-to-high-temperature electrochemical devices. While there is increasing interest in low-temperature preparation of MIEC thin films, the impact of the resultant varied degrees of crystallinity on the surface exchange kinetics has not been widely investigated. Herein, we probe the effect of crystallization on oxygen surface exchange kinetics in situ, by applying an optical transmission relaxation (OTR) approach during annealing of amorphous films. OTR enables contact-free, in situ, and continuous quantification of the oxygen surface exchange coefficient ( k chem ); we previously applied it to Pr x Ce 1– x O 2-δ and SrTi 1– x Fe x O 3-δ thin films. In this work, the OTR approach was successfully extended to other mixed conducting thin film compositions for the first time (i.e., perovskite SrTi 0.65 Co 0.35 O 3-δ and Ruddlesden–Popper Sr 2 Ti 0.65 Fe 0.35 O 4±δ ), as well as to Pr 0.1 Ce 0.9 O 2-δ , enabling quantification of the k chem of their native surfaces and comparison of the behavior of films with different final crystal structures. All thin films were prepared by pulsed laser deposition at 25 or 700–800 °C and subject to subsequent thermal treatments with simultaneous OTR monitoring of k chem . The surface roughness, grain size, and crystallinity were evaluated by scanning probe microscopy, X-ray diffraction, scanning electron microscopy, and transmission electron microscopy. Fluorite Pr 0.1 Ce 0.9 O 2-δ films grown at 25 °C did not exhibit an increase in k chem after annealing, as they were already crystalline as grown at 25 °C. For all other compositions, OTR enabled in situ observation of both the crystallization process and the emergence of rapid surface exchange kinetics immediately upon crystallization. Perovskite SrTi 0.65 Co 0.35 O 3-δ and Ruddlesden–Popper Sr 2 Ti 0.65 Fe 0.35 O 4±δ thin films grown at 25 °C exhibited at least 1–2 orders of magnitude enhanced k chem after annealing compared with highly crystalline thin films grown at 800 °C, indicating the benefits of in situ crystallization.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Soil gas probes for monitoring trace gas messengers of microbial activity

Abstract Soil microbes vigorously produce and consume gases that reflect active soil biogeochemical processes. Soil gas measurements are therefore a powerful tool to monitor microbial activity. Yet, the majority of soil gases lack non-disruptive subsurface measurement methods at spatiotemporal scales relevant to microbial processes and soil structure. To address this need, we developed a soil gas sampling system that uses novel diffusive soil probes and sample transfer approaches for high-resolution sampling from discrete subsurface regions. Probe sampling requires transferring soil gas samples to above-ground gas analyzers where concentrations and isotopologues are measured. Obtaining representative soil gas samples has historically required balancing disruption to soil gas composition with measurement frequency and analyzer volume demand. These considerations have limited attempts to quantify trace gas spatial concentration gradients and heterogeneity at scales relevant to the soil microbiome. Here, we describe our new flexible diffusive probe sampling system integrated with a modified, reduced volume trace gas analyzer and demonstrate its application for subsurface monitoring of biogeochemical cycling of nitrous oxide (N 2 O) and its site-specific isotopologues, methane, carbon dioxide, and nitric oxide in controlled soil columns. The sampling system observed reproducible responses of soil gas concentrations to manipulations of soil nutrients and redox state, providing a new window into the microbial response to these key environmental forcings. Using site-specific N 2 O isotopologues as indicators of microbial processes, we constrain the dynamics of in situ microbial activity. Unlocking trace gas messengers of microbial activity will complement -omics approaches, challenge subsurface models, and improve understanding of soil heterogeneity to disentangle interactive processes in the subsurface biome.

04 OIL SHALES AND TAR SANDS↗

DOE OSTI2025

Investigation of In Situ and Ex Situ Passivation of Pyrophoric Uranium–Niobium Alloy Powder

This work evaluates the effectiveness of in situ and ex situ passivation methods for mitigating the pyrophoricity of uranium–6 wt.% niobium spherical powders produced via the hydride–dehydride process coupled with plasma spheroidization. Oxide layer thickness was characterized using STEM/EDX, and pyrophoricity was assessed by a UN-recommended test method, which involves directly dropping the powders in the air. In situ passivation, performed by introducing flowing oxygen during spheroidization, produced oxide layers ranging from tens to hundreds of nanometers but resulted in inconsistent pyrophoricity mitigation at lower oxygen flow rates. Ex situ passivation, achieved by slow oxygen exposure over several months, formed uniform oxide layers of approximately 20 nm and consistently mitigated pyrophoricity. Despite requiring higher bulk oxygen content, in situ passivation enables faster processing and control of oxygen, while ex situ passivation achieves superior oxide uniformity with lower oxygen incorporation. These findings highlight the trade-offs between passivation methods and provide a foundation for improving the safety and scalability of reactive metal powder production.

U-6Nb↗

DOE OSTI2015

Fabrication and Cytocompatibility of In Situ Crosslinked Carbon Nanomaterial Films

Assembly of carbon nanomaterials into two-dimensional (2D) coatings and films that harness their unique physiochemical properties may lead to high impact energy capture/storage, sensors and biomedical applications. For potential biomedical applications, the suitability of current techniques such as chemical vapor deposition, spray and dip coating and vacuum filtration, employed to fabricate macroscopic 2D all carbon coatings or films still requires thorough examination. Each of these methods presents challenges with regards to scalability, suitability for a large variety of substrates, mechanical stability of coatings or films, or biocompatibility. Herein we report a coating process that allow for rapid, in situ chemical crosslinking of multi-walled carbon nanotubes (MWCNTs) into macroscopic all carbon coatings. The resultant coatings were found to be continuous, electrically conductive, significantly more robust and cytocompatible to human adipose derived stem cells. The results lay groundwork for 3D layer-on-layer nanomaterial assemblies (including various forms of graphene) and also opens avenues to further explore the potential of MWCNT films as a novel class of nano-fibrous mats for tissue engineering and regenerative medicine.

Science & Technology - Other Topics↗

DOE OSTI2022

Design and Challenges of Edge Computing ASICs on Front-End Electronics

In situ or hardware-embedded data processing of raw signals, close to their source, in radiation detectors is expected to provide dramatic improvements in data quality and volumes. However, the implementation of artificial neural networks (ANNs) in the front-end electronics, and the design of custom integrated circuits (ASICs), comes with challenges. In addition, detectors have to operate with limited power budget and implement complex functionalities in a very dense space. They often are exposed to extreme conditions as they work in high-radiation environments and/or cryogenic temperatures. This paper presents examples of applications and design methodologies for in-situ ANNs, along with the challenges of retaining the fidelity of the trained networks. For illustration, we use the problem of estimating the energy deposited by the radiation from digitized waveforms. The proposed implementation starts with an ML algorithm trained in Qkeras and eventually leads to an equivalent ASIC implementation. The associated design challenges in realizing energy and area efficient implementations in CMOS processes are reviewed. Novel approaches that employ hybrid technologies (combination of CMOS with memristors), in-memory computing models, and bio-inspired spiking neural networks are also highlighted

47 OTHER INSTRUMENTATION↗

NASA NTRS2017

Snow Accumulation Variability on a West Antarctic Ice Stream Observed with GPS Reflectometry, 2007-2017

Land ice loss from Antarctica is a significant and accelerating contribution to global sea level rise; however, Antarctic mass balance estimates are complicated by insufficient knowledge of surface mass balance processes such as snow accumulation. Snow accumulation is challenging to observe on a continental scale and in situ data are sparse, so we largely rely on estimates from atmospheric models. Here we employ a novel technique, GPS interferometric reflectometry (GPS-IR), to measure upper (less than 2 m) firn column thickness changes across a 23-station GPS array in West Antarctica. We compare the results with antenna heights measured in situ to establish the method's daily uncertainty (0.06 m) and with output from two atmospheric reanalysis products to categorize spatial and temporal variability of net snow accumulation. GPS-IR is an effective technique for monitoring surface mass balance processes that can be applied to both historic GPS data sets and future experiments to provide critical in situ observations of processes driving surface height evolution.

snow↗

DOE OSTI2024

Towards in-situ certification of additively manufactured parts: the vital roles of physics-based and data-driven models

Certifying additively manufactured (AM) parts in-situ at the completion of a build is an enticing prospect, as it can help reduce the high costs associated with post-build testing and evaluation. However, achieving this goal presents significant challenges that may keep it aspirational for the foreseeable future. Nonetheless, incremental progress can pave the way forward. A critical aspect of in-situ certification involves continuous quality checking due to the random nature of the AM process and the difficulties in detecting defects or anomalies once layers are built over. While real-time in-situ monitoring strategies assisted by machine learning (ML) play a pivotal role in auditing part quality, they must ideally be supported by real-time (or near real-time) adaptive process control enabled by ML-assisted decision-making. By analyzing in-situ monitoring data in real-time (or near real- time) to dynamically adjust manufacturing parameters, such intervention can ensure AM parts are built to meet stringent certification standards. This can be achieved virtually by using high-fidelity performance models for the physical testing and evaluation tasks. In this short editorial, we discuss the key contributions made by data-driven and physics-based models in providing intelligence to the monitoring and process control tasks underpinning in-situ certification and in the simulation of the build’s performance under test and service conditions. While our focus lies in metal AM, the concepts discussed here are also relevant to other AM processes.

: In-situ monitoring↗

DOE OSTI2019

Radiological Verification for the Remediation of LLRW at the Port Granby Project - 19210

The Port Granby Project is part of the Port Hope Area Initiative (PHAI) that Canadian Nuclear Laboratory (CNL) is using to manage long-term historic low level radioactive waste (LLRW) resulting from 60 years of uranium and radium processing operations in the urban setting of Port Hope, Ontario. Port Granby remediation scope includes constructing a new, secure long-term waste management facility (LTWMF) and supporting infrastructure and excavating and relocating LLRW and marginally contaminated soil from the Port Granby Waste Management Facility (PGWMF) which accepted waste until the 1980's to the newly constructed LTWMF. The PGWMF contains an estimated 450,000 cubic meters of LLRW deposited in unmarked and unlined trenches throughout the southern portion of the site that borders Lake Ontario. Project requirements include excavating contaminated material, verifying that the trench bottoms are below action levels using Multi-Agency Radiation Survey and Site Investigation Manual (MARSSIM) guidance, and final restoration. This paper describes challenges of meeting remediation verification requirements using traditional field and laboratory confirmation methods in areas of deep trench areas located in rugged terrain with ponded water and mud and presents a process that has expedited the traditional MARSSIM method for verification with greater productivity, and with enhanced safety and reliability as compared to the use of traditional methods alone. This enhanced process has been successfully employed for in-situ verification so that the excavated area can be backfilled and returned to a vegetative state. This enhanced process has been examined by federal regulatory staff through the course of their onsite audits and outcomes from these examinations have all been positive. The method involves a visual inspection and traditional walkover of the area to identify any areas with radiation measurements above the region's background followed by a full area survey performed using Wood's proprietary Orion ScanPlotSM system. The ScanPlotSM data is evaluated, mapped and overlaid on top of an aerial image of the surveyed area allowing remaining radiological material at surface or near surface to be quickly and easily identified for removal. Field staff then collect soil samples from evenly distributed points within the surveyed area and field screen the samples using an X-ray fluorescence (XRF) analysis for the three primary contaminates of potential concern (CoPCs) (arsenic, uranium and lead) that are indicative of the historical contamination. Samples passing XRF field screening are packaged and sent to a local laboratory for a full suite of analyses and checked against the CoPC list to assess whether the soil matches the profile for nearby native soils and passes the remediation goals. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2015

On The Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in-situ materials will become increasingly critical. As man's presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in-situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. This is important because gamma and particle radiation constitute a serious but reducible threat to long-term survival of human beings, electronics, and other materials in space environments. Also, it is anticipated that surface structures will constitute the primary mass element of lunar or Martian launch requirements. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for self-sufficiency necessary for long-duration habitation. Previously, under the auspices of the MSFC In Situ Fabrication and Repair (ISFR) project and more recently, under the joint MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in situ resources. One such technology, known as Contour Crafting (additive construction), is shown in Figure 1, along with a typical structure fabricated using this technology. This paper will present the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using the Contour Crafting process. This process, conceived initially for rapid development of cementitious structures on Earth, also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and imported binder material or binders developed from in situ materials. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. These binder materials have resulted from extensive evaluation and include both "imported" binder materials that might be launched from Earth as well as some binder materials that can theoretically also be derived from existing regolith materials. They were chosen to 1) reduce penetrating radiation as much as possible, primarily with hydrogen-bearing polymers, 2) attempt to provide an air-tight structure, 3) sufficiently mix and adsorb to regolith grains for strength, 4) maximize tolerance to day-night thermal cycling, 5) possibly increase electrical conductivity to dissipate any accumulated static charge, and 6) ease their application on planetary surfaces (specifically, the accommodation of reduced atmosphere and lack of heat sinks). Some of these materials have been tested with respect to radiation mitigation, micrometeorite resistance, and resistance to larger, slower-traveling pieces of regolith impinging on the surface, simulating nearby launch and landing activities. Conceptual designs for a Continuous Feedstock Delivery/Mixing System (CFDMS) will also be presented and future planned activities will be discussed as well.

Werkheiser, Niki↗