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NASA NTRS2006

Status of NASA's Advanced Radioisotope Power Conversion Technology Research and Development

NASA s Advanced Radioisotope Power Systems (RPS) development program is funding the advancement of next generation power conversion technologies that will enable future missions that have requirements that can not be met by either the ubiquitous photovoltaic systems or by current Radioisotope Power Systems (RPS). Requirements of advanced radioisotope power systems include high efficiency and high specific power (watts/kilogram) in order to meet mission requirements with less radioisotope fuel and lower mass. Other Advanced RPS development goals include long-life, reliability, and scalability so that these systems can meet requirements for a variety of future space applications including continual operation surface missions, outer-planetary missions, and solar probe. This paper provides an update on the Radioisotope Power Conversion Technology Project which awarded ten Phase I contracts for research and development of a variety of power conversion technologies consisting of Brayton, Stirling, thermoelectrics, and thermophotovoltaics. Three of the contracts continue during the current Phase II in the areas of thermoelectric and Stirling power conversion. The accomplishments to date of the contractors, project plans, and status will be summarized.

Wong, Wayne A.↗

NASA NTRS1988

The US space station and its electric power system

The United States has embarked on a major development program to have a space station operating in low earth orbit by the mid-1990s. This endeavor draws on the talents of NASA and most of the aerospace firms in the U.S. Plans are being pursued to include the participation of Canada, Japan, and the European Space Agency in the space station. From the start of the program these was a focus on the utilization of the space station for science, technology, and commercial endeavors. These requirements were utilized in the design of the station and manifest themselves in: pressurized volume; crew time; power availability and level of power; external payload accommodations; microgravity levels; servicing facilities; and the ability to grow and evolve the space station to meet future needs. President Reagan directed NASA to develop a permanently manned space station in his 1984 State of the Union message. Since then the definition phase was completed and the development phase initiated. A major subsystem of the space station is its 75 kW electric power system. The electric power system has characteristics similar to those of terrestrial power systems. Routine maintenance and replacement of failed equipment must be accomplished safely and easily and in a minimum time while providing reliable power to users. Because of the very high value placed on crew time it is essential that the power system operate in an autonomous mode to minimize crew time required. The power system design must also easily accommodate growth as the power demands by users are expected to grow. An overview of the U.S. space station is provided with special emphasis on its electrical power system.

Thomas, Ronald L.↗

NASA NTRS1981

Solar cell development for the power extension package

The PEP is a 32 kilowatt flexible substrate, retrievable, solar array system for use on the Space Shuttle. Solar cell costs will be reduced by increasing cell area and simplifying cell and coverglass fabrication processes and specifications. The cost goal is to produce cells below $30 per watt. Two and ten ohm-cm silicon cells were investigated. In phase I of the cell development program a few thousand candidate cells will be produced and evaluated for utility and quality. In phase II a large number of cells will be fabricated to verify production readiness and cell yields and costs. This schedule is compatible with PEP initial operational capability in 1984. Approximately 140,000 large area (5.9 x 5.9 cm) cells will be required for two PEP solar arrays. The status of the cell development and testing, including a radiation damage test and side-by-side comparison of candidate cell types with pre- and post-irradiation airplane calibration of outer space short-circuit current, is reported.

Baraona, C. R.↗

NASA NTRS1981

Sensitivity analysis of the add-on price estimate for the silicon web growth process

The web growth process, a silicon-sheet technology option, developed for the flat plate solar array (FSA) project, was examined. Base case data for the technical and cost parameters for the technical and commercial readiness phase of the FSA project are projected. The process add on price, using the base case data for cost parameters such as equipment, space, direct labor, materials and utilities, and the production parameters such as growth rate and run length, using a computer program developed specifically to do the sensitivity analysis with improved price estimation are analyzed. Silicon price, sheet thickness and cell efficiency are also discussed.

Mokashi, A. R.↗

NASA NTRS1993

Appendix A: Proposed statement of work, 1994

This NRA effort is devoted to developing new techniques and methodologies which utilize and/or provide support to Integrated Vehicle Health Management (IVHM) concepts and techniques, modern design processes, and open architectures to realize an avionics system architecture that relieves the flight control system (FCS) of the requirement of maintaining intimate knowledge and control of the vehicle subsystems (for instance, the reaction control system (RCS)). The benefit of this architecture is that future upgrades and enhancements to the system(s) or to individual components within the system(s) are greatly simplified. This approach also allows a much more straightforward treatment of failure analysis, system diagnosis, and the design of fault containment domains. This NRA effort is also devoted to realizing capabilities to provide an available avionics system (and subsystem(s)) at minimum operational cost. This thrust provides a direct benefit to NASA in that it seeks to accelerate the design cycle to allow state of the art components and designs to actually appear in the fielded system rather than merely in the initial design. To achieve this, this effort is intended to benefit from efforts already underway at Lockheed and other major contractors. For instance, Lockheed Sanders is currently engaged in a major DoD funded development program which has the goal of cutting design cycle time of high performance electronics by a factor of four while simultaneously improving quality also by a factor of four. The early work on this program was used to enable the rapid prototyping of the Reaction Jet Drive Controller which was accomplished in 1993. Similarly, maximum leverage will be derived from recent NASA and DoD efforts to increase the content of high quality commercial grade electronic components in systems for aerospace applications. Both of these goals result in a system with enhanced cost effectiveness, increased reliability, and greatly increased performance compared to a system developed using a more conventional approach.

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NASA NTRS2001

Life Prediction Issues in Thermal/Environmental Barrier Coatings in Ceramic Matrix Composites

Issues and design requirements for the environmental barrier coating (EBC)/thermal barrier coating (TBC) life that are general and those specific to the NASA Ultra-Efficient Engine Technology (UEET) development program have been described. The current state and trend of the research, methods in vogue related to the failure analysis, and long-term behavior and life prediction of EBCITBC systems are reported. Also, the perceived failure mechanisms, variables, and related uncertainties governing the EBCITBC system life are summarized. A combined heat transfer and structural analysis approach based on the oxidation kinetics using the Arrhenius theory is proposed to develop a life prediction model for the EBC/TBC systems. Stochastic process-based reliability approach that includes the physical variables such as gas pressure, temperature, velocity, moisture content, crack density, oxygen content, etc., is suggested. Benefits of the reliability-based approach are also discussed in the report.

Shah, Ashwin R.↗

NASA NTRS2007

Application of Risk within Net Present Value Calculations for Government Projects

In January 2004, President Bush announced a new vision for space exploration. This included retirement of the current Space Shuttle fleet by 2010 and the development of new set of launch vehicles. The President's vision did not include significant increases in the NASA budget, so these development programs need to be cost conscious. Current trade study procedures address factors such as performance, reliability, safety, manufacturing, maintainability, operations, and costs. It would be desirable, however, to have increased insight into the cost factors behind each of the proposed system architectures. This paper reports on a set of component trade studies completed on the upper stage engine for the new launch vehicles. Increased insight into architecture costs was developed by including a Net Present Value (NPV) method and applying a set of associated risks to the base parametric cost data. The use of the NPV method along with the risks was found to add fidelity to the trade study and provide additional information to support the selection of a more robust design architecture.

Grandl, Paul R.↗

NASA NTRS1992

The development of nickel-metal hydride technology for use in aerospace applications

The nickel metal hydride technology for battery application is relatively immature even though this technology was made widely known by Philips' scientists as long ago as 1970. Recently, because of the international environmental regulatory pressures being placed on cadmium in the workplace and in disposal practices, battery companies have initiated extensive development programs to make this technology a viable commercial operation. These hydrides do not pose a toxilogical threat as does cadmium. Also, they provide a higher energy density and specific energy when compared to the other nickel based battery technologies. For these reasons, the nickel metal hydride electrochemisty is being evaluated as the next power source for varied applications such as laptop computers, cellular telephones, electric vehicles, and satellites. A parallel development effort is under way to look at aerospace applications for nickel metal hydride cells. This effort is focused on life testing of small wound cells of the commercial type to validate design options and development of prismatic design cells for aerospace applications.

Rampel, Guy↗

NASA NTRS2002

Thermal Gradient Cyclic Behavior of a Thermal/Environmental Barrier Coating System on SiC/SiC Ceramic Matrix Composites

Thermal barrier and environmental barrier coatings (TBCs and EBCs) will play a crucial role in future advanced gas turbine engines because of their ability to significantly extend the temperature capability of the ceramic matrix composite (CMC) engine components in harsh combustion environments. In order to develop high performance, robust coating systems for effective thermal and environmental protection of the engine components, appropriate test approaches for evaluating the critical coating properties must be established. In this paper, a laser high-heat-flux, thermal gradient approach for testing the coatings will be described. Thermal cyclic behavior of plasma-sprayed coating systems, consisting of ZrO2-8wt%Y2O3 thermal barrier and NASA Enabling Propulsion Materials (EPM) Program developed mullite+BSAS/Si type environmental barrier coatings on SiC/SiC ceramic matrix composites, was investigated under thermal gradients using the laser heat-flux rig in conjunction with the furnace thermal cyclic tests in water-vapor environments. The coating sintering and interface damage were assessed by monitoring the real-time thermal conductivity changes during the laser heat-flux tests and by examining the microstructural changes after the tests. The coating failure mechanisms are discussed based on the cyclic test results and are correlated to the sintering, creep, and thermal stress behavior under simulated engine temperature and heat flux conditions.

Zhu, Dongming↗

NASA NTRS1993

Air Force brush seal programs

Aggressive pursuit of increased performance in gas turbine engines is driving the thermodynamic cycle to higher pressure ratios, bypass ratios, and turbine inlet temperatures. As these parameters increase, internal air system and resultant thermodynamic cycle losses increase. This conflict of reducing internal airflows while increasing thermodynamic efficiency and performance is putting more emphasis on improvements to the internal flow system. One improvement that has been and continues to be pursued by the Air Force for both man-rated and expendable turbine engine applications is the brush seal. This presentation briefly describes both past and current brush seal research and development programs and gives a summary of demonstrator and developmental engine testing of brush seals.

Dowler, Connie↗

NASA NTRS1983

Energy efficient engine, high pressure turbine thermal barrier coating. Support technology report

This report describes the work performed on a thermal barrier coating support technology task of the Energy Efficient Engine Component Development Program. A thermal barrier coating (TBC) system consisting of a Ni-Cr-Al-Y bond cost layer and ZrO2-Y2O3 ceramic layer was selected from eight candidate coating systems on the basis of laboratory tests. The selection was based on coating microstructure, crystallographic phase composition, tensile bond and bend test results, erosion and impact test results, furnace exposure, thermal cycle, and high velocity dynamic oxidation test results. Procedures were developed for applying the selected TBC to CF6-50, high pressure turbine blades and vanes. Coated HPT components were tested in three kinds of tests. Stage 1 blades were tested in a cascade cyclic test rig, Stage 2 blades were component high cycle fatigue tested to qualify thermal barrier coated blades for engine testing, and Stage 2 blades and Stage 1 and 2 vanes were run in factory engine tests. After completion of the 1000 cycle engine test, the TBC on the blades was in excellent condition over all of the platform and airfoil except at the leading edge above midspan on the suction side of the airfoil. The coating damage appeared to be caused by particle impingement; adjacent blades without TBC also showed evidence of particle impingement.

Duderstadt, E. C.↗

NASA NTRS1986

Wall Interference in Two-Dimensional Wind Tunnels

Viscosity and tunnel-wall constraints introduced via boundary conditions. TWINTN4 computer program developed to implement method of posttest assessment of wall interference in two-dimensional wind tunnels. Offers two methods for combining sidewall boundary-layer effects with upper and lower wall interference. In sequential procedure, Sewall method used to define flow free of sidewall effects, then assessed for upper and lower wall effects. In unified procedure, wind-tunnel flow equations altered to incorporate effects from all four walls at once. Program written in FORTRAN IV for batch execution.

Kemp, William B., Jr.↗

NASA NTRS1991

Results of prototype software development for automation of shuttle proximity operations

A Rendezvous Expert System (REX) was implemented on a Symbolics 3650 processor and integrated with the 6 DOF, high fidelity Systems Engineering Simulator (SES) at the NASA Johnson Space Center in Houston, Texas. The project goals were to automate the terminal phase of a shuttle rendezvous, normally flown manually by the crew, and proceed automatically to docking with the Space Station Freedom (SSF). The project goals were successfully demonstrated to various flight crew members, managers, and engineers in the technical community at JSC. The project was funded by NASA's Office of Space Flight, Advanced Program Development Division. Because of the complexity of the task, the REX development was divided into two distinct efforts. One to handle the guidance and control function using perfect navigation data, and another to provide the required visuals for the system management functions needed to give visibility to the crew members of the progress being made towards docking the shuttle with the LVLH stabilized SSF.

Hiers, Harry K.↗

NASA NTRS1994

Activity Catalog Tool (ACT) user manual, version 2.0

This report comprises the user manual for version 2.0 of the Activity Catalog Tool (ACT) software program, developed by Leon D. Segal and Anthony D. Andre in cooperation with NASA Ames Aerospace Human Factors Research Division, FLR branch. ACT is a software tool for recording and analyzing sequences of activity over time that runs on the Macintosh platform. It was designed as an aid for professionals who are interested in observing and understanding human behavior in field settings, or from video or audio recordings of the same. Specifically, the program is aimed at two primary areas of interest: human-machine interactions and interactions between humans. The program provides a means by which an observer can record an observed sequence of events, logging such parameters as frequency and duration of particular events. The program goes further by providing the user with a quantified description of the observed sequence, through application of a basic set of statistical routines, and enables merging and appending of several files and more extensive analysis of the resultant data.

Segal, Leon D.↗

NASA NTRS1982

Large area low-cost space solar cell development

A development program to produce large-area (5.9 x 5.9 cm) space quality silicon solar cells with a cost goal of 30 $/watt is descibed. Five cell types under investigation include wraparound dielectric, mechanical wraparound and conventional contact configurations with combinations of 2 or 10 ohm-cm resistivity, back surface reflectors and/or fields, and diffused or ion implanted junctions. A single step process to cut cell and cover-glass simultaneously is being developed. A description of cell developments by Applied Solar Energy Corp., Spectrolab and Spire is included. Results are given for cell and array tests, performed by Lockheed, TRW and NASA. Future large solar arrays that might use cells of this type are discussed.

Baraona, C. R.↗

NASA NTRS1987

Optimal Network-Topology Design

Candidate network designs tested for acceptability and cost. Optimal Network Topology Design computer program developed as part of study on topology design and analysis of performance of Space Station Information System (SSIS) network. Uses efficient algorithm to generate candidate network designs consisting of subsets of set of all network components, in increasing order of total costs and checks each design to see whether it forms acceptable network. Technique gives true cost-optimal network and particularly useful when network has many constraints and not too many components. Program written in PASCAL.

Li, Victor O. K.↗

NASA NTRS1988

Molecular-Beam-Epitaxy Program

Molecular Beam Epitaxy (MBE) computer program developed to aid in design of single- and double-junction cascade cells made of silicon. Cascade cell has efficiency 1 or 2 percent higher than single cell, with twice the open-circuit voltage. Input parameters include doping density, diffusion lengths, thicknesses of regions, solar spectrum, absorption coefficients of silicon (data included for 101 wavelengths), and surface recombination velocities. Results include maximum power, short-circuit current, and open-circuit voltage. Program written in FORTRAN IV.

Sparks, Patricia D.↗

NASA NTRS1989

Toward an electrical power utility for space exploration

Plans for space exploration depend on today's technology programs addressing the novel requirements of space-based enterprise. The requirements for electrical power will be formidable: megawatts in magnitude, reliability for multi-year missions and the flexibility to adapt to needs unanticipated at design time. The reasons for considering the power management and distribution in the various systems from a total mission perspective, rather than simply extrapolating current spacecraft design practice, are discussed. A utility approach to electric power being developed at the Lewis Research Center is described. It integrates requirements from a broad selection of current development programs with studies in which both space and terrestrial technologies are conceptually applied to exploration mission scenarios.

Bercaw, Robert W.↗