Results for “supply chain optimization” — Page 9

NASA NTRSDate not supplied

Development of Two High-Energy Bus ‘Cores’

For several years the TechEdSat flight series (TES-n), developed by the Nano Orbital Workshop (NOW) group at NASA Ames, has relied upon an in-house developed unit to serve both EPS (Electrical Power System) and C&DH (Command and Data Handling) roles along with low data-rate telemetry functions, i.e., serving as the ‘core’ of the spacecraft bus. This ‘core’ has a considerable task given the rapid cadence of the TES program and the typically low-TRL of payloads; configurability and compatibility are key to prevent mission-specific hardware. However, at only 15 watts the current core has become insufficient to support the program’s growing missions and increasingly demanding payloads. To this end, the NOW program is developing new cores to support two TES mission classes: a single-PCB ‘MiniCore’ designed to support 80-watt missions 6U or smaller in LEO, and a three-PCB, radiation-tolerant ‘StackCore’ designed to support 6U and larger missions over 500 watts in LEO and beyond. The ‘MiniCore’ design consists of three main segments: a processor-agnostic C&DH, a software-configured EPS, and a backup low data-rate radio. The design philosophy was to enable rapid-manufacture in a turbulent supply chain, hence the design consists of COTS parts with a focus on those able to be drop-in replaced with radiation-tolerant versions when demanded by the mission. As a single PC-104 sized circuit board, power density and ease of integration also dominated design, demanding the use of modern features such as single-point USB-C for easy charging and monitoring of the spacecraft on the ground. The ‘MiniCore’ can support 80 watts of load, 140 watt-hours of storage, and over 20 watts of optimized solar generation with extensive power monitoring throughout. The ‘MiniCore’ supports one battery pack, six solar-panels, six loads, five actuators, Iridium SBD, and an internal 802.15.4 network. Additionally, the processor-agnostic design can accept any PJRC Teensy 3.x or Adafruit Feather microcontroller unit to enable processor scaling with mission requirements or environment. It is expected a development unit of this design will be completed before conference. The ‘StackCore’ design consists of three stacked PC-104 sized circuit boards: one dedicated to power generation and storage, one dedicated to power distribution, and one dedicated to C&DH tasks. This delineation is necessary to support the transition from highly integrated ICs to discrete analog circuitry, enabling a primarily analog control power system able to operate without software in a radiation environment with finer monitoring compared to the ‘MiniCore’ design. The planned base architecture supports over 500 watts of load, 250 watt-hours of storage, and over 80 watts of optimized solar generation. The power distribution board allows for the use of daughter cards hosting custom converters or interfaces for payloads, in addition to the software-configured supplies used on the ‘MiniCore’. This core stack will be managed by a Vorago ARM M4 microcontroller and support the same wireless communications as the ‘MiniCore’, with optional integration of a NOW S-band radio and attitude determination sensors for ‘black box’ functionality. It is expected the prototype will still be in development during conference.

Avery Brock↗

DOE OSTI2023

Contact pressure analysis to allow improved design for the clearing plate in a biomass comminution system

For biomass processing systems, feedstocks with small but equal sizes can improve flowability and thermochemical outputs. The Crumbler rotary shear system was designed to achieve such ideal feedstocks to reduce costs and energy throughout the biomass supply chain. Improving the wear resistance of major components in this system is important to decrease the cost. Accelerating the feedstock flow through the rotary shear machine plays an equivalent role of improving its efficiency. An analytical analysis and a finite-element analysis of the stationary clearing plate are presented in this work. Here, these tools are used to investigate the effect of contact surface curvature on the impact pressure. The optimized new clearing plate design is expected to improve the component’s lifetime and wood chips flowability. The field tests confirm that the trend of the new clearing plate design guided by FEA. The optimization method, model verification, and validation experience applied in this work can also be applied to other static components with similar simple contact wear problems.

09 BIOMASS FUELS↗

DOE OSTI2025

Coal to Carbon Fiber (C2CF) Continuous Processing for High Value Composites (Final Report)

Coal tar is a condensed and recovered by-product of the coking of metallurgical coal for steel production. The heaviest fraction of distilled coal tar is an isotropic pitch largely used as a binder in the manufacturing of carbonaceous electrodes for primary aluminum smelting and in electric arc furnaces. Coal tar pitch offers high carbon yield upon carbonization. In this project, a process to convert the domestically sourced isotropic coal tar pitch, containing very low particulates (QI = 0.32 wt.%), to form flow-domain mesophase pitch amenable for melt spinning into precursor (green) fibers for carbon fiber, was developed and optimized. The final reproducible processing developed is reviewed in this report, along with several characterizations of the mesophase pitch. A final definition of the characteristics of a ‘spinnable’ mesophase pitch is presented. With this mesophase pitch, reproducible and stable multifilament melt spinning was developed, producing green fiber tows with filament diameters of approximately 20 m. The multifilament melt spinning was the most challenging aspect of the project and required the most effort. The best practices learned from this project for melt spinning are reviewed in this report. Once spun, the green fibers were oxidatively stabilized, carbonized and graphitized under inert gas atmosphere to form the final carbon fibers. Given the relatively high softening point of the mesophase pitch, no issues of interfilament fusion were observed during batch oxidation, and subsequent batch carbonization and graphitization went smoothly in all cases. An ~ 80 wt.% conversion of the green fiber mass to final carbon fiber was achieved. After graphitization, the carbon fibers showed high tensile moduli (most were ~ 600 GPa, or 87 Msi) consistent with commercially-available high-performance pitch-based carbon fiber. However, tensile strength and strain to failure were comparatively low. Further work to reduce defects in and on the fiber surfaces would increase these properties. SEM imaging of the graphitic fiber textures is presented herein. Rudimentary composites were fabricated from the carbon fibers and characterized showing similar modulus to baseline composites fabricated with commercial carbon fiber. Finally, a basic economic analysis was done showing the potential to increase the value of the isotropic coal tar pitch by up to 13.6 to 136 times based on a carbon fiber value of $\$$5/lb to $\$$50/lb, respectively. Moreover, the site case study suggests that the coal tar from the single integrated steel mill could supply production of up to 16 kt/yr of carbon fiber. Finally, a technological gap analysis was done which shed light on remaining technical challenges. These challenges included: recovery and utilization of condensates from the mesophase pitch processing, further advancing and increasing stability of the multifilament melt spinning processing, optimization of the oxidation processing, defect reduction for increased carbon fiber strength, and the development of a weaving process towards carbon fiber fabrics. To maximize the coal value chain, the primary objectives of this project were to (a) develop and scale efficient processing technology for producing melt-spinnable mesophase pitch from isotropic coal tar pitch, (b) clarify and simplify tedious continuous fiber processing technologies (particularly multifilament melt spinning of mesophase pitch) towards the efficient production of high performance carbon fiber, and (c) demonstrate and characterize representative composite parts derived from the final carbon fiber. Immense progress was made on all 3 objectives and is detailed in this report.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Evaluation of DED and LPBF Fe-based Alloys Process Application Envelopes based on Performance, Process Economics, Supply Chain Risks, and Reactor-specific Targeted Components

The U.S. Department of Energy (DOE), Office of Nuclear Energy (NE), Advanced Materials and Manufacturing Technologies (AMMT) program aims to develop extreme-environment materials solutions for use in the deployment of advanced nuclear reactors and the sustainment of the current fleet. To achieve this objective, a combination of experiment, a computational tool, and machine learning (ML) for the design of materials is adopted for the maturation of materials for nuclear technology. Through advanced manufacturing techniques such as laser powder bed fusion (LPBF) and laser powder direct energy deposition (LP-DED), components with complex geometries can be fabricated with reduced time and effort. Such advanced manufacturing methods can also provide the opportunity to improve materials performance through optimized microstructures and mechanical properties. However, existing engineering alloys are not always well suited for fabrication with additive manufacturing (AM), as their compositions have been tuned to optimize fabrication via conventional methods. Thus, similar alloys with modified compositions that are better suited for AM can be studied for improved performance. Over the past three years, the AMMT teams from Argonne National Laboratory (ANL) and Pacific Northwest National Laboratory (PNNL) studied various known Fe-based alloys by evaluating their initial printability using LPBF, and an AMMT-developed down-selection and decision matrix reduced the number of alloys to be studied from six to three in fiscal year (FY) 2024. Additionally, in FY 2024, for parallel evaluation, these three alloys were studied using LPDED. While LPBF is better for small- to medium-sized components with high detail and internal features, LP-DED combines a material feed system to place the powder onto the exact spot where the laser will melt the material. This AM method can be easily scaled to extremely large components and provides high build rate speeds compared to those of conventional LPBF systems. Additionally, DED is a better choice for complex geometries and compositional gradients.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

U.S. Trends on MEA Architectures

The presentation discusses background, current industry status in the US, potential future novel pathways, and challenges to a broad understanding of and optimal decision about the architecture of PEM fuel cell MEAs. This is not an original research paper, it is my observation and perspective on technology status, as requested for the scope of the workshop.

ENGINEERING,MATERIALS SCIENCE↗

NASA NTRS2023

Progressively Enabling Earth Independent Medical Operations (EIMO)

This panel presents the findings from a series of Technical Interchange Meetings (TIMs) hosted by the Exploration Medical Capability Element (ExMC) in NASA’s Human Research Program. The topics for the TIMs were derived from a 2-day conference of senior leaders and subject matters experts that collectively outlined a multi-faceted strategy designed to optimize crew health and performance through an increasingly autonomous medical approach. The first abstract in this panel outlines the scope of issues related to data collection, usage, transmission and computing capacity to facilitate EIMO. The second presentation provides an overview of the challenges in developing curricula and advanced training tools to baseline knowledge, skills and abilities (KSA), verify clinical competency and assure retention during prolonged durations inherent in exploration-class missions. An overview of the complicated medical supply and resource chain necessary to facilitate EIMO is provided in the third presentation of this panel. The final presentation in this EIMO panel surveys the breadth and depth of demands on cognitive load expected to be experienced by crew on an exploration mission and proposes strategies to mitigate the prospect of cognitive overload through methods to shift task load from the crew to multi-modal artificial intelligence based medical support systems. Taken together, these presentations summarize the challenges to be expected and potential solution spaces to be explored and developed to progressively enable increasing autonomous medical operations to support crewed missions beyond low earth orbit. Through EIMO focused pre-mission planning, integrated data architecture design, innovative training development and AI-assisted task load management, the gradual transition of medical care and decision making from terrestrial to space-based assets enabling support of astronaut health and performance and reducing overall mission risk is achievable.

Jay Lemery↗

NASA NTRSDate not supplied

Progressively Enabling Earth Independent Medical Operations (EIMO)

This panel presents the findings from a series of Technical Interchange Meetings (TIMs) hosted by the Exploration Medical Capability Element (ExMC) in NASA’s Human Research Program. The topics for the TIMs were derived from a 2-day conference of senior leaders and subject matters experts that collectively outlined a multi-faceted strategy designed to optimize crew health and performance through an increasingly autonomous medical approach. The first abstract in this panel outlines the scope of issues related to data collection, usage, transmission and computing capacity to facilitate EIMO. The second presentation provides an overview of the challenges in developing curricula and advanced training tools to baseline knowledge, skills and abilities (KSA), verify clinical competency and assure retention during prolonged durations inherent in exploration-class missions. An overview of the complicated medical supply and resource chain necessary to facilitate EIMO is provided in the third presentation of this panel. The final presentation in this EIMO panel surveys the breadth and depth of demands on cognitive load expected to be experienced by crew on an exploration mission and proposes strategies to mitigate the prospect of cognitive overload through methods to shift task load from the crew to multi-modal artificial intelligence based medical support systems. Taken together, these presentations summarize the challenges to be expected and potential solution spaces to be explored and developed to progressively enable increasing autonomous medical operations to support crewed missions beyond low earth orbit. Through EIMO focused pre-mission planning, integrated data architecture design, innovative training development and AI-assisted task load management, the gradual transition of medical care and decision making from terrestrial to space-based assets enabling support of astronaut health and performance and reducing overall mission risk is achievable.

John Lemery↗

DOE OSTI2021

Recent developments in filtration media and respirator technology in response to COVID-19

Abstract The COVID-19 pandemic triggered a surge in demand for N95 or equivalent respirators that the global supply chain was unable to satisfy. This shortage in critical equipment has inspired research that addresses the immediate problems and has accelerated the development of the next-generation filtration media and respirators. This article provides a brief review of the most recent work with regard to face respirators and filtration media. We discuss filtration efficiency of the widely utilized cloth masks. Next, the sterilization of and reuse of existing N95 respirators to extend the existing stockpile is discussed. To expand near-term supplies, optimization of current manufacturing methods, such as melt-blown processes and electrospinning, has been explored. Future manufacturing methods have been investigated to address long-term supply shortages. Novel materials with antiviral and sterilizable properties with the ability for multiple reuses have been developed and will contribute to the development of the next generation of longer lasting multi-use N95 respirators. Finally, additively manufactured respirators are reviewed, which enable a rapidly deployable source of reusable respirators that can use any filtration fabric. Graphic abstract

36 MATERIALS SCIENCE↗

DOE OSTI2023

Marine Alternative Fuel Pricing, Supply, and Demand

The International Maritime Organization low sulfur fuel rules and greenhouse gas-reduction strategy may create a significant perturbation to global refinery operations, impacting volumes and prices of marine fuel globally and within the United States and incentivizing the transition to alternative fuel use. The goals of this project are to (1) enhance understanding of how very low-sulfur fuel-primarily fuel oil and diesel-and low carbon fuel requirements and promising biofuel processes will affect the marine fuel supply chain; and (2) explore how these perturbations interact with and impact indicators such as pricing, number of trips, and demand behavior, along with the potential to meet low sulfur and carbon fuel demand with biofuel supply chains, (3) merge innovative thinking in the area of marine fuels within research centers of DOE (NREL) and the U.S. Department of Transportation (Volpe). These goals will be accomplished through the combination of detailed refinery, marine fuel burn, system dynamics, and geospatially explicit linear programming models.

biofuel↗

DOE OSTI2025

The Triple Catalytic Action of Tertiary Nitrogen Catalysts in Recyclable Epoxy-Anhydride Thermosets

The thermosetting polymer matrix in fiber reinforced composites is an important component for energy related applications, such as the lightweighting of vehicles or their use in wind and waterpower turbine blades, due to their ability to provide superior adhesion, stiffness, and applicability to a wide range of manufacturing processes. Despite these benefits, today's thermosets are widely considered to be unrecyclable; thus, there is a large interest in redesigning these materials to be inherently recyclable so that energy intensive production of fibers and monomers can be circumvented, bolstering composite manufacture supply chains. Polyester covalent adaptable networks (PECANs) are one such promising alternative to the incumbent, nonrecyclable epoxy-amine thermosets. PECANs can be formed from the ring-opening co-polymerization (ROCOP) of epoxy-anhydride monomer mixtures and subsequent curing at mild temperatures to exhibit similar performance to conventional epoxies while also possessing unique dynamic chemistries along the ester-hydroxyl backbone that are capable of transesterification and thus reprocessability. While significant advancements have been made in formulating these materials for improved mechanical properties or optimizing solvolysis and reprocessing strategies, less attention has been placed on the impact of the residing amine catalyst used to generate the polyester network. In this work, we evaluated the triple-catalytic efficacy of 12 tertiary amines that act as a curing (bulk ROCOP), a transesterification (internal bond exchange), and a deconstruction (methanolysis) catalyst for PECAN thermosets. Specifically, we first distinguish between chain-growth and step-growth polymerization mechanisms for epoxy-amine and epoxy-anhydride mechanisms. We also utilized density functional theory (DFT) to estimate the basicity (pKb) of each catalyst. Of the tested catalysts, the ROCOP of the studied PECAN network can be completed between 95 and 247 min (at 80 degrees C), with variable gelation phenomena. Additionally, the stress relaxation (transesterification metric) efficiency of the tested PECAN networks with alternative embedded catalysts ranged from 95% to 15% reduction in stress after 5 h at 200 degrees C, and the depolymerization efficacy ranged from 2.5% to 9.8% deconstruction after 36 h at 130 degrees C. Overall, the nitrogen-based moieties were demonstrated to influence polymerization kinetics, catalyze the dynamic transesterification exchange mechanism, and aid in the solvolysis of the thermosets at end-of-life.

36 MATERIALS SCIENCE↗

DOE OSTI2020

High-throughput screening for discovery of benchtop separations systems for selected rare earth elements

Abstract Rare earth (RE) elements (scandium, yttrium, and the lanthanides) are critical for their role in sustainable energy technologies. Problems with their supply chain have motivated research to improve separations methods to recycle these elements from end of life technology. Toward this goal, we report the synthesis and characterization of the ligand tris[(1-hydroxy-2-oxo-1,2-dihydropyridine-3-carboxamido)ethyl]amine, H 3 1·TFA (TFA = trifluoroacetic acid), and complexes 1·RE (RE = La, Nd, Dy). A high-throughput experimentation (HTE) screen was developed to quantitatively determine the precipitation of 1·RE as a function of pH as well as equivalents of H 3 1·TFA. This method rapidly determines optimal conditions for the separation of RE mixtures, while minimizing materials consumption. The HTE-predicted conditions are used to achieve the lab-scale separation of Nd/Dy ( SF Nd/Dy = 213 ± 34) and La/Nd ( SF La/Nd = 16.2 ± 0.2) mixtures in acidic aqueous media.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Integrated Energy Systems Program Management Plan

In 2012, the U.S. Department of Energy (DOE) Office of Nuclear Energy (NE) initiated the Nuclear Energy Enabling Technology Program, which includes the Crosscutting Technology Development (CTD) portfolio of subprograms, to conduct research, development, and demonstration (RD&D) to support existing, new and advanced reactor designs and fuel cycle technologies. This program plan describes the Integrated Energy Systems (IES) Program, an element of the CTD portfolio since 2016 that seeks to improve the economic competitiveness, efficiency and environmental performance of nuclear energy systems by expanding their potential application space beyond electricity and optimizing their utilization in the context of the larger U.S. electric and non-electric energy system.

08 HYDROGEN↗

DOE OSTI2024

Modeling hydrogen markets: Energy system model development status and decarbonization scenario results

Hydrogen can be used as an energy carrier and chemical feedstock to reduce greenhouse gas emissions, especially in difficult-to-decarbonize markets such as medium- and heavy-duty vehicles, aviation and maritime, iron and steel, and the production of fuels and chemicals. Significant literature has been accumulated on engineering-based assessments of various hydrogen technologies, and real-world projects are validating technology performance at larger scales and for low-carbon supply chains. While energy system models continue to be updated to track this progress, many are currently limited in their representation of hydrogen, and as a group they tend to generate highly variable results under decarbonization constraints. Here, the present work provides insights into the development status and decarbonization scenario results of 15 energy system models participating in study 37 of the Stanford Energy Modeling Forum (EMF37), focusing on the U.S. energy system. The models and scenario results vary widely in multiple respects: hydrogen technology representation, scope and type of hydrogen end-use markets, relative optimism of hydrogen technology input assumptions, and market uptake results reported for 2050 under various decarbonization assumptions. Most models report hydrogen market uptake increasing with decarbonization constraints, though some models report high carbon prices being required to achieve these increases and some find hydrogen does not compete well when assuming optimistic assumptions for all advanced decarbonization technologies. Across various scenarios, hydrogen market success tends to have an inverse relationship to success with direct air capture (DAC) and carbon capture and storage (CCS) technologies. While most model-scenario combinations predict modest hydrogen uptake by 2050 – <10 million metric tons (MMT) – aggregating the top 10 % of market uptake results across sectors suggests an upper range demand potential of 42–223 MMT. The high degree of variability across both modeling methods and market uptake results suggests that increased harmonization of both input assumptions and subsector competition scope would lead to more consistent results across energy system models. The wide variability in results indicates strongly divergent conclusions on the role of hydrogen in a decarbonized energy future.

08 HYDROGEN↗

DOE OSTI2021

Impacts of turbine and plant upsizing on the levelized cost of energy for offshore wind

Turbine and plant upsizing are major trends in offshore wind deployment, although the quantitative impact on project costs has not been well-characterized. The uncertain value of continued wind turbine and project growth limits the ability of the supply chain to prepare for future technology trends, leading to challenges in the realization of larger projects. This analysis explores the levelized cost of energy impacts of turbine ratings between 6 and 20 MW and plant capacities between 250 and 2,500 MW for fixed-bottom offshore wind using techno-economic cost models for foundation, electrical, installation, and operation and maintenance costs, along with annual energy production. We consider a nominal set of technology assumptions for all scenarios to isolate economies of size and scale without additional benefits from decreasing turbine capital costs, quantity discounts for larger projects, or optimized technology solutions. These results indicate that using a 20-MW wind turbine in a 2,500-MW power plant array can reduce the levelized cost of energy by over 23% relative to the global average turbine and plant size installed in 2019; primarily because of reductions in the balance-of-system and operation and maintenance costs. We also identify improved installation vessels, optimized export systems, and novel operation and maintenance strategies as additional cost reduction opportunities. These results suggest that upsizing represents a significant cost reduction opportunity for offshore wind energy and will continue to be a main factor in shaping the future of the sector.

17 WIND ENERGY↗

NASA NTRS2017

Carbon-Carbon Nozzle Extension Development in Support of In-Space and Upper-Stage Liquid Rocket Engines

Upper stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures, increasing exhaust velocities. Due to the large size of such nozzles, and the related engine performance requirements, carbon-carbon (C-C) composite nozzle extensions are being considered to reduce weight impacts. Currently, the state-of-the-art is represented by the metallic and foreign composite nozzle extensions limited to approximately 2000 degrees F. used on the Atlas V, Delta IV, Falcon 9, and Ariane 5 launch vehicles. NASA and industry partners are working towards advancing the domestic supply chain for C-C composite nozzle extensions. These development efforts are primarily being conducted through the NASA Small Business Innovation Research (SBIR) program in addition to other low level internal research efforts. This has allowed for the initial material development and characterization, subscale hardware fabrication, and completion of hot-fire testing in relevant environments. NASA and industry partners have designed, fabricated and hot-fire tested several subscale domestically produced C-C extensions to advance the material and coatings fabrication technology for use with a variety of liquid rocket and scramjet engines. Testing at NASA's Marshall Space Flight Center (MSFC) evaluated heritage and state-of-the-art C-C materials and coatings, demonstrating the initial capabilities of the high temperature materials and their fabrication methods. This paper discusses the initial material development, design and fabrication of the subscale carbon-carbon nozzle extensions, provides an overview of the test campaign, presents results of the hot fire testing, and discusses potential follow-on development work. The follow on work includes the fabrication of ultra-high temperature materials, larger C-C nozzle extensions, material characterization, sub-element testing and hot-fire testing at larger scale.

Gradl, Paul R.↗

NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗

NASA NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗

DOE OSTI2024

A sustainable cobalt separation with validation by techno-economic analysis and life-cycle assessment

Sustainable, cost-effective cobalt/nickel separations chemistry contributes to the realization of economically competitive lithium-ion battery recycling, as well as primary mining of cobalt and nickel. Such improvements can address supply chain challenges for cobalt, a critical element. Herein, we disclose a simple method for separating Co/Ni by second coordination-sphere molecular recognition. Selective cobalt precipitation is achieved using carbonate ions in an ammonia solution due to the outer-sphere, hydrogen bonding interactions between [Co(NH 3 ) 6 ] 3+ and CO 3 2− , evaluated with density functional theory calculations. We demonstrate this method on mixtures of Co/Ni chlorides comprising a 10-fold excess of Ni and provide comparisons with ore-processing systems. High purities (99.4(3)% Co; 98.2(4)% Ni) and recoveries (77(8)% Co; ∼100% Ni) were observed for both Co- and Ni-enriched products using optimized conditions. In conclusion, this method is potentially economically competitive based on initial techno-economic analysis (TEA) and life-cycle assessment (LCA) that also illustrate advantages in terms of sustainability.

cobalt↗