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NASA NTRS1995

Composite heat pipe development status: Development of lightweight prototype carbon-carbon heat pipe with integral fins and metal foil liner

This report discusses development and proof-of-concept testing of a new lightweight carbon-carbon (C-C) space radiator heat pipe, carried out under the NASA Civil Space Technology Initiative (CSTI) High Capacity Power Program. The prototype heat pipe, equipped with a niobium-zirconium foil liner, was filled with potassium working fluid and tested for 11 hours, including startup from ambient temperature with the working fluid initially in the frozen state to near 700 K condenser temperature. Steady-state heat pipe input power during testing was facility limited to about 300 watts. Post test inspection showed the heat pipe to be in excellent condition after eight thermal cycles from ambient to steady-state operating temperature. Utilization of other liner materials and working fluids would greatly extend the spectrum of service temperatures for this technology, with potential applications ranging from small spacecraft heat rejection to aircraft and terrestrial uses.

Juhasz, Albert J.↗

NASA NTRS1995

Wideband fixed-tuned SIS receiver for 200-GHz operation

We report on the design and development of a heterodyne receiver, designed to cover the frequency range 176-256 GHz. This receiver incorporates a niobium superconductor-insulator-superconductor (SIS) tunnel junction mixer, which, chiefly for reasons of reliability and ease of operation, is a fixed-tuned waveguide design. On-chip tuning is provided to resonate out the junction's geometric capacitance and produce a good match to the waveguide circuit. Laboratory measurements on the first test receiver indicate that the required input bandwidth (about 40%) is achieved with an average receiver noise temperature of below 50 K. Mixer conversion gain is observed at some frequencies, and the lowest measured receiver noise is less than 30 K. Furthermore, the SIS mixer used in this receiver is of simple construction, is easy to assemble and is therefore a good candidate for duplication.

RECEIVER NOISE TEMPERATURE↗

NASA NTRS1995

190-GHz radiation from a quasioptical Josephson junction array

At 190 GHz, 0.36 micro W has been detected from an 11 x 58 array of niobium Josephson junctions. The power is radiated directly into free space above the surface of the two-dimensional array of junctions. Detection is made by a commercial bolometer outside the array cryostat. The junctions in the array are closely spaced in the y-dimension, but spaced by more than one-half wavelength in the x-direction. This asymmetry results in mutual phase-locking between adjacent junctions suitable for the production of y-polarized radiation. The resonance and asymmetry also result in a reasonable impedance match between the Josephson junctions and the free-space radiation mode.

ARRAY CRYOSTAT↗

NASA NTRS1995

A study of the superconducting properties of YBa2Cu(9-x)Nb(x)O(y) thin films

Effect of Niobium substitution at the copper site in YBa2Cu3O(7-x) was studied in thin film form. The films were deposited by laser ablation technique using the targets of the YBa2Cu(3-x)Nb(x)O(y) where x = 0.0, 0.025, 0.05, 0.1, 0.2, 0.4, 0.8 and 1.0 under identical deposition conditions on SrTiO3 (100) substrates. Films were characterized by XRD, resistivity, I-V and J(sub c) measurements. Films made from x = 0.025 and 0.05 concentrations of Nb substituted targets showed relatively improved superconducting properties compared to that of undoped films. the best J(sub c) realized for x - 0.025 Nb concentration was 1.8 x 10(exp 6) A/sq cm and for 0.05 Nb concentration it was 3.2 x 10(exp 6) A/sq cm at 77 K. However, degradation of the superconducting properties, with the increase of x is greater than or equal to 0.1 Nb concentration and drastic suppression and complete loss of superconductivity was noticed for x is greater than or equal to 0.4. The growth of impurity phase YBa2NbO6 for x = 0.1 and above of Nb concentration was noted from XRD (X-Ray Diffraction) patterns. However, the site occupancy of Nb could not be confirmed from these studies.

Srinivas, S.↗

NASA NTRS1995

Evaluation of Rhenium Joining Methods

Coupons of rhenium-to-Cl03 flat plate joints, formed by explosive and diffusion bonding, were evaluated in a series of shear tests. Shear testing was conducted on as-received, thermally-cycled (100 cycles, from 21 to 1100 C), and thermally-aged (3 and 6 hrs at 1100 C) joint coupons. Shear tests were also conducted on joint coupons with rhenium and/or Cl03 electron beam welded tabs to simulate the joint's incorporation into a structure. Ultimate shear strength was used as a figure of merit to assess the effects of the thermal treatment and the electron beam welding of tabs on the joint coupons. All of the coupons survived thermal testing intact and without any visible degradation. Two different lots of as-received, explosively-bonded joint coupons had ultimate shear strengths of 281 and 310 MPa and 162 and 223 MPa, respectively. As-received, diffusion-bonded coupons had ultimate shear strengths of 199 and 348 MPa. For the most part, the thermally-treated and rhenium weld tab coupons had shear strengths slightly reduced or within the range of the as-received values. Coupons with Cl03 weld tabs experienced a significant reduction in shear strength. The degradation of strength appeared to be the result of a poor heat sink provided during the electron beam welding. The Cl03 base material could not dissipate heat as effectively as rhenium, leading to the formation of a brittle rhenium-niobium intermetallic.

Reed, Brian D.↗

NASA NTRS1995

Robotic Planetary Science Missions Enabled with Small NTR Engine/Stage Technologies

The high specific impulse (Isp) and engine thrust-to-weight ratio of liquid hydrogen (LH2)-cooled nuclear thermal rocket (NTR) engines makes them ideal for upper stage applications to difficult robotic planetary science missions. A small 15 thousand pound force (klbf) NTR engine using a uranium-zirconium-niobium 'ternary carbide' fuel (Isp approximately 960 seconds at approximately 3025K) developed in the Commonwealth of Independent States (CIS) is examined and its use on an expendable injection stage is shown to provide major increases in payload delivered to the outer planets (Saturn, Uranus, Neptune and Pluto). Using a single 'Titan IV-class' launch vehicle, with a lift capability to low Earth orbit (LEO) of approximately 20 metric tons (t), an expendable NTR upper stage can inject two Pluto 'Fast Flyby' spacecraft (PFF/SC) plus support equipment-combined mass of approximately 508 kg--on high energy, '6.5-9.2 year' direct trajectory missions to Pluto. A conventional chemical propulsion mission would use a liquid oxygen (LOX)/LH2 'Centaur' upper stage and two solid rocket 'kick motors' to inject a single PFF/SC on the same Titan IV launch vehicle. For follow on Pluto missions, the NTR injection stage would utilize a Jupiter 'gravity assist' (JGA) maneuver to launch a LOX/liquid methane (CH4) capture stage (Isp approximately 375 seconds) and a Pluto 'orbiter' spacecraft weighing between approximately 167-312 kg. With chemical propulsion, a Pluto orbiter mission is not a viable option because c inadequate delivered mass. Using a 'standardized' NTR injection stage and the same single Titan IV launch scenario, 'direct flight' (no gravity assist) orbiter missions to Saturn, Uranus and Neptune are also enabled with transit times of 2.3, 6.6, and 12.6 years, respectively. Injected mass includes a storable, nitrogen tetroxide/monomethyl hydrazine (N2O4/MMH) capture stage (Isp approximately 330 seconds) and orbiter payloads 340 to 820% larger than that achievable using a LOX/LH2-fueled injection stage. The paper discusses NTR technology and mission characteristics, shows NTR stage and payload accommodations within the 26.2 m long Titan IV payload fairing, and discusses NTR stage performance as a function of assumed cryogenic tank technology.

Borowski, Stanley K.↗

NASA NTRS1997

Iridium-Coated Rhenium Radiation-Cooled Rockets

Radiation-cooled rockets are used for a range of low-thrust propulsion functions, including apogee insertion, attitude control, and repositioning of satellites, reaction control of launch vehicles, and primary propulsion for planetary space- craft. The key to high performance and long lifetimes for radiation-cooled rockets is the chamber temperature capability. The material system that is currently used for radiation-cooled rockets, a niobium alloy (C103) with a fused silica coating, has a maximum operating temperature of 1370 C. Temperature limitations of C103 rockets force the use of fuel film cooling, which degrades rocket performance and, in some cases, imposes a plume contamination issue from unburned fuel. A material system composed of a rhenium (Re) substrate and an iridium (Ir) coating has demonstrated operation at high temperatures (2200 C) and for long lifetimes (hours). The added thermal margin afforded by iridium-coated rhenium (Ir/Re) allows reduction or elimination of fuel film cooling. This, in turn, leads to higher performance and cleaner spacecraft environments. There are ongoing government- and industry-sponsored efforts to develop flight Ir/ Re engines, with the primary focus on 440-N, apogee insertion engines. Complementing these Ir/Re engine development efforts is a program to address specific concerns and fundamental characterization of the Ir/Re material system, including (1) development of Ir/Re rocket fabrication methods, (2) establishment of critical Re mechanical properly data, (3) development of reliable joining methods, and (4) characterization of Ir/Re life-limiting mechanisms.

Reed, Brian D.↗

NASA NTRS1996

Oxygen Interaction With Space-Power Materials

Four investigations were undertaken during the period of this grant: (1 ) oxidation of molybdenum and of niobium-1 % zirconium, (2) preparation of and examination of EOIM-3 samples, (3) sputtering of Teflon by oxygen ion bombardment,and (4) sputtering of Ions from copper and aluminum by oxygen and argon ion bombardment. Investigations (1), (3), and (4) used a low-energy Ion gun to bombard surfaces within an ultra-high vacuum system. Particles ejected from the surfaces were detected by a mass spectrometer.

Eck, Thomas G.↗

NASA NTRS1998

Development Study of Cartridge/Crucible Tube Materials

The limitations of traditional alloys and the desire for improved performance for components is driving the increased utilization of refractory metals in tile space industry. From advanced propulsion systems to high temperature furnace components for microgravity processing, refractory metals are being used for their high melting temperatures and inherent chemical stability. Techniques have been developed to produce near net shape refractory metal components utilizing vacuum plasma spraying. Material utilization is very high, and laborious machining can be avoided. As-spray formed components have been tested and found to perform adequately. However, increased mechanical and thermal properties are needed. To improve these properties, post processing thermal treatments such as hydrogen sintering and vacuum annealing have been performed. Components formed from alloys of tungsten, rhenium, tantalum, niobium, and molybdenum are discussed and a metallurgical analyses detailing the results are presented. A qualitative comparison of mechanical properties is also included.

McKechnie, Timothy N.↗

NASA NTRS1997

Precise Measurements of the Density and Critical Phenomena Near Phase Transitions in Liquid Helium

The first-year progress for the project of precise measurements of the density and critical phenomena of helium near phase transitions is summarized below: (1) completion of a cryogenic sample probe for the proposed measurements, and the rehabilitation of a designated laboratory at Caltech for this project; (2) construction and testing of a superconducting niobium cavity; (3) acquisition of one phase-locked-loop system for high-resolution frequency control and read- out; (4) setting up high-resolution thermometry (HRT) for temperature readout and control; (5) developing new approaches for calibrating the coefficient between the resonant frequency shift (delta f) and the helium density (rho), as well as for measuring the effect of gravity on T(sub lambda) to a much better precision; (6) programming of the interface control of all instruments for automatic data acquisition; and (7) improving data analyses and fitting procedures.

Yeh, Nai-Chang↗

NASA NTRS1998

Airborne Submillimeter Spectroscopy

This is the final technical report for NASA-Ames grant NAG2-1068 to Caltech, entitled "Airborne Submillimeter Spectroscopy", which extended over the period May 1, 1996 through January 31, 1998. The grant was funded by the NASA airborne astronomy program, during a period of time after the Kuiper Airborne Observatory was no longer operational. Instead. this funding program was intended to help develop instrument concepts and technology for the upcoming SOFIA (Stratospheric Observatory for Infrared Astronomy) project. SOFIA, which is funded by NASA and is now being carried out by a consortium lead by USRA (Universities Space Research Association), will be a 747 aircraft carrying a 2.5 meter diameter telescope. The purpose of our grant was to fund the ongoing development of sensitive heterodyne receivers for the submillimeter band (500-1200 GHz), using sensitive superconducting (SIS) detectors. In 1997 July we submitted a proposal to USRA to construct a heterodyne instrument for SOFIA. Our proposal was successful [1], and we are now continuing our airborne astronomy effort with funding from USRA. A secondary purpose of the NAG2-1068 grant was to continue the anaIN'sis of astronomical data collected with an earlier instrument which was flown on the NASA Kuiper Airborne Observatory (KAO). The KAO instrument and the astronomical studies which were carried out with it were supported primarily under another grant, NAG2-744, which extended over October 1, 1991 through Januarv 31, 1997. For a complete description of the astronomical data and its anailysis, we refer the reader to the final technical report for NAG2-744, which was submitted to NASA on December 1. 1997. Here we report on the SIS detector development effort for SOFIA carried out under NAG2-1068. The main result of this effort has been the demonstration of SIS mixers using a new superconducting material niobium titanium nitride (NbTiN), which promises to deliver dramatic improvements in sensitivity in the 700-1200 GHz frequency range.

Zmuidzinas, J.↗

NASA NTRS1998

Flexible Ceramic-Metal Insulation Composite and Method of Making

A method for joining a woven flexible ceramic fabric and a thin metal sheet creating an integral metal surfaced flexible thermal protection article, which methods compress: placing multiple dots of high temperature metallic or fabric and the thin metal sheet in a random or organized pattern, with the proviso that the brazing material covers about 10% or less of the surface of one flat side of the metal sheet; heating the flexible ceramic fabric, brazing material and thin metal sheet for a predetermined period of time to integrally connect the same; and cooling the formed flexible article to ambient temperature. Preferably the flexible ceramic is selected from fibers comprising atoms of silicon, carbon, nitrogen, boron, oxygen or combinations thereof. The flexible thermal protection article produced is also part of the present invention. The thin metal sheet is comprised of titanium, aluminum, chromium, niobium or alloys or combinations thereof. The brazing material is selected from copper/silver or copper/gold or is a ceramic brazing or adhesive material.

Rasky, Daniel J.↗

NASA NTRS1996

Large Bandwidth and Low Noise in a Diffusion-Cooled Hot-Electron Bolometer Mixer

Heterodyne measurements have been made at 533 GHz using a novel superconducting hot-electron bolometer in a waveguide mixer. The bolometer is a 0.3 micrometer long niobium microbridge with a superconducting transition temperature of 5 K. The short length ensures that electron diffusion dominates over electron-phonon interactions as the electron cooling mechanism, which should allow heterodyne detection with intermediate frequencies (if) of several GHz. A Y-factor response of 1.15 dB has been obtained at an if of 1.4 GHz with 77 and 295 K loads, indicating a receiver noise temperature of 650 K DSB. The -3 dB rolloff in the if response occurs at 1.7 GHz.

Skalare, A.↗

NASA NTRS2000

A Dual Polarized Quasi-Optical SIS Mixer at 550-GHz

We describe the design, fabrication, and the performance of a low-noise dual-polarized quasi-optical superconductor insulator superconductor (SIS) mixer at 550 GHz. The mixer utilizes a novel cross-slot antenna on a hyperhemispherical substrate lens, two junction tuning circuits, niobium trilayer junctions, and an IF circuit containing a lumped element 180 deg hybrid. The antenna consists of an orthogonal pair of twin-slot antennas, and has four feed points, two for each polarization. Each feed point is coupled to a two-junction SIS mixer. The 180 deg IF hybrid is implemented using a lumped element/microstrip circuit located inside the mixer block. Fourier transform spectrometer (FTS) measurements of the mixer frequency response show good agreement with computer simulations. The measured co-polarized and cross-polarized patterns for both polarizations also agree with the theoretical predictions. The noise performance of the dual-polarized mixer is excellent, giving uncorrected receiver noise temperature of better than 115 K (DSB) at 528 GHz for both the polarizations.

Chattopadhyay, Goutam↗

NASA NTRS2000

Lightweight Chambers for Thrust Cell Applications

Traditional metals like steel and copper alloys have been used for many years to fabricate injector and chamber components of thruster assemblies. While the materials perform well, reducing engine weights would help existing and future vehicles gain performance and payload capability. It may now be possible to reduce current thruster weights up to 50% by applying composite materials. In this task, these materials are being applied to an existing thrust cell design to demonstrate new fabrication processes and potential weight savings. Two ceramic matrix composite (CMC) designs, three polymer matrix composite (PMC) designs, and two metal matrix composite (MMC) designs are being fabricated as small chamber demonstration units. In addition, a new alloy of copper, chrome, and niobium (Cu-8Cr-4Nb) is being investigated for thrust chamber liners since it offers higher strength and increased cycle life over traditional alloys. This new alloy is being used for the liner in each MMC and PMC demonstration unit. During June-August of 2000, hot-fire testing of each unit is planned to validate designs in an oxygen/hydrogen environment at chamber pressures around 850 psi. Although the weight savings using CMC materials is expected to be high, they have proven to be much harder to incorporate into chamber designs based on current fabrication efforts. However, the PMC & MMC concepts using the Cu-8Cr-4Nb liner are nearly complete and ready for testing. Additional efforts intend to use the PMC & MMC materials to fabricate a full size thrust chamber (60K lb(sub f) thrust class). The fabrication of this full size unit is expected to be complete by October 2000, followed by hot-fire testing in November-December 2000.

Elam, S.↗

NASA NTRS1999

Precise Frequency Measurements Using a Superconducting Cavity Stabilized Oscillator

Many physics experiments call on improved resolution to better define the experimental results, thus improving tests of theories. Modern microwave technology combined with high-Q resonators can achieve frequency readout and control with resolutions up to a part in 10(exp 18). When the physical quantity in question in the experiment can be converted to a frequency or a change in frequency, a high-stability microwave oscillator can be applied to obtain state-of-the-art precision. In this work we describe the overall physical concepts and the required experimental procedures for optimizing a high-resolution frequency measurement system that employs a high-Q superconducting microwave cavity and a low-noise frequency synthesizer. The basic approach is to resolve the resonant frequencies of a high-Q (Q > 10(exp 10)) cavity to extremely high precision (one part in 10(exp 17)- 10(exp 18)). Techniques for locking the synthesizer frequency to a resonant frequency of the superconducting cavity to form an ultra-stable oscillator are described. We have recently set up an ultra-high-vacuum high-temperature annealing system to process superconducting niobium cavities, and have been able to consistently achieve Q > 10(exp 9). We have integrated high-Q superconducting cavities with a low-noise microwave synthesizer in a phase-locked-loop to verify the frequency stability of the system. Effects that disturb the cavity resonant frequency (such as the temperature fluctuations and mechanical vibrations) and methods to mitigate those effects are also considered. Applicability of these techniques to experiments will be discussed, and our latest experimental progress in achieving high-resolution frequency measurements using the superconducting-cavity-stabilized-oscillator will be presented.

Strayer, D. M.↗

NASA NTRS2001

A Low-Noise NbTiN Hot Electron Bolometer Mixer

Hot electron bolometer (HEB) mixer elements, based on niobium titanium nitride (NbTiN) thin film technology, have been fabricated on crystalline quartz substrates over a 20 nm thick AlN buffer layer. The film was patterned by optical lithography, yielding bolometer elements that measure about 1 micrometer long and between 2 and 12 micrometers wide. These mixer chips were mounted in a fixed-tuned waveguide mixer block, and tested in the 600 and 800 GHz frequency range. The 3-dB output bandwidth of these mixers was determined to be about 2.5 GHz and we measured a receiver noise temperature of 270 K at 630 GHz using an intermediate frequency of 1.5 GHz. The receiver has excellent amplitude stability and the noise temperature measurements are highly repeatable. An 800 GHz receiver incorporating one of these mixer chips has recently been installed at the Sub-Millimeter Telescope in Arizona for field test and for astronomical observations.

Tong, C. Edward↗

NASA NTRS2002

Microelectric Heterogeneous Hybrid Devices for Space Applications

The existing projects designated as SACA (Sample Ampoule Cartridge/Container Assembly) and QMI (Quench Module Insert) at NASA's MSFC (Marshall Space Flight Center) involve development of high-temperature coating materials. A number of material systems need to be evaluated for this purpose. The requirement of these coating materials included high emissivity (approaching unity), sufficient physical strength, appropriate thermal conductivity to dissipate heat, and above all high temperature (T is equal to or greater than 2000 C) withstanding capability. Potential materials for applications considered were non-oxide based materials such as tungsten carbide, tantalum carbide, compounds of niobium, etc.

Mohammad A. Alim↗