In-Space Manufacturing: An Overview of Current Technologies, Challenges, and Pathways for Sustainable Deep-Space Exploration
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Alam kabhi, Ahsanul [Louisiana Tech University]↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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2018 Conference on Advanced Power Systems for Deep Space Exploration presentation - eMMRTG Development and Infusion
Presentation of the status of the enhance Multi-Mission Radioisotope Thermoelectric Generator (eMMRTG). The presentation describes the MMRTG and details the eMMRTG program goals. The presentation then describes the expected generator performance as the fuel decays over the 17 year life without any thermoelectric degradation and how the end user can design to maximize performance.
30 DIRECT ENERGY CONVERSION↗
VASIMR{sup R} Interfaced High Temperature Gas-Cooled Fast Reactor for Space Applications
This project was undertaken to assess the feasibility and advantages of utilizing a gas-cooled fast reactor to supply power to an electric propulsion system for deep space exploration to Europa, one of Jupiter's moons. Specifically, the primary objective of this project was to design a 9 MWe gas cooled fast reactor with an accompanying power conversion system to supply electricity to multiple electrically-powered thrusters for a four year mission duration. The thruster design chosen for this analysis is the Variable Specific Impulse Magnetoplasma Rocket (VASIMR). The VASIMR propulsion system, currently being developed by Ad Astra Rocket Company (AARC), is an electric propulsion rocket that uses electric power to accelerate neutral plasma propellant. Advanced electric space propulsion systems such as the VASIMR offer unique capabilities that allow for higher exhaust velocities that are up to ten times that of traditional chemical rockets. Furthermore, the thrust and specific impulse of the VASIMR system can be varied in order to achieve optimal travel times to given destinations for a desired payload. As a result, electric propulsion systems characteristically have lower ratios of system mass to power output than chemical rockets. This ratio is commonly known as the alpha parameter. Alpha parameters of approximately 10 kg/kWe or less make electric propulsion more attractive for deep space exploration missions in terms of resource efficiency and cost. However, the primary challenge with electric propulsion is to develop a high power density source of electricity in order to minimize the total system mass. The alpha parameter is the main benchmark used in this project to test whether or not the proposed coupled gas cooled reactor and power conversion system design is more competitive than other proposed systems. (authors)
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
On-demand fabrication of piezoelectric sensors for in-space structural health monitoring
Abstract Inflatable structures, promising for future deep space exploration missions, are vulnerable to damage from micrometeoroid and orbital debris impacts. Polyvinylidene fluoride-trifluoroethylene (PVDF-trFE) is a flexible, biocompatible, and chemical-resistant material capable of detecting impact forces due to its piezoelectric properties. This study used a state-of-the-art material extrusion system that has been validated for in-space manufacturing, to facilitate fast-prototyping of consistent and uniform PVDF-trFE films. By systematically investigating ink synthesis, printer settings, and post-processing conditions, this research established a comprehensive understanding of the process-structure-property relationship of printed PVDF-trFE. Consequently, this study consistently achieved the printing of PVDF-trFE films with a thickness of around 40 µ m, accompanied by an impressive piezoelectric coefficient of up to 25 pC N −1 . Additionally, an all-printed dynamic force sensor, featuring a sensitivity of 1.18 V N −1 , was produced by mix printing commercial electrically-conductive silver inks with the customized PVDF-trFE inks. This pioneering on-demand fabrication technique for PVDF-trFE films empowers future astronauts to design and manufacture piezoelectric sensors while in space, thereby significantly enhancing the affordability and sustainability of deep space exploration missions.
Instruments & Instrumentation↗
ORNL automates key process in plutonium-238 production
Oak Ridge National Laboratory scientists have automated part of the process of producing plutonium-238, which is used by NASA to fuel deep space exploration. Resolving this key bottleneck will help boost annual production of the radioisotope towards NASA’s goal of 1.5 kilograms of Pu-238 per year by 2025.
07 ISOTOPE AND RADIATION SOURCES↗
Star Truck : Interplanetary Bussing system
CubeSats are a standardized size of satellite. Used by elementary schools, universities, and hobbyists alike. CubeSats have made space exploration and research accessible to the general population. Utilizing CubeSats it is possible to make deep space exploration accessible as well. Using a flight path that takes advantage of gravitational assists and flybys we can use many forms of propulsion to get to Jupiter. However, to get farther nuclear power and propulsion can be utilized to bus hundreds of CubeSats at a time to interplanetary space. This craft is known as a Star Truck. The Star Truck will make interplanetary space assessable to the common man.
Belian, Olivia↗
Foreword Special issue on the Kilopower Project, Kilowatt Reactor Using Stirling TechnologY (KRUSTY) Test
This special issue of Nuclear Technology contains full-length, peer-reviewed papers describing the design work leading up to and the results of the Kilowatt Reactor Using Stirling TechnologY (KRUSTY) test. KRUSTY was the centerpiece of the National Aeronautics and Space Administration (NASA) Kilopower Project to design, build, and test a space nuclear reactor. This test was the first such test since the end of the Space Nuclear Auxiliary Power (SNAP) project at the end of the 1960s. In this issue, the introduction paper presents the goals of the Kilopower Project and the potential missions this reactor concept could serve in NASA. Kilopower was intended to serve both human exploration needs on planetary surfaces as well as science needs for deep-space exploration. The design work for the experiment by Poston and the power conversion development by Gibson present the pre-work required to perform the eventual KRUSTY test. A paper on regulatory analysis follows, to show the path used to gain approval of the proposed experiment. Then, the early zero-power critical experiments are presented by Sanchez and Grove. These experiments were essential data used to enhance model predictions prior to the high-temperature test. Next, Poston presents the three experiments (warm criticals) that increase the temperature in an incremental fashion prior to the final experiment. These experiments were used to achieve final regulatory approval of the final high-temperature experiment. The last paper by Poston presents the results of the steady-state and transient testing of the reactor at full power and at the design temperature. These results show that the reactor design and as-built experiment met all of the requirements that NASA had developed for the system. Any experiment of this magnitude was accomplished only because of the hard work and dedication of a large number of people at multiple institutions, including the NASA Glenn Research Center, NASA Marshall Space Flight Center, Y-12 National Security Site, Los Alamos National Laboratory, and the Nevada National Security Site prime contractor (formerly National Security Technologies and now the Mission Support and Test Services). The project was jointly funded by the Space Technology Mission Directorate at NASA and the Criticality Safety Program at the National Nuclear Security Administration (NNSA). A special thanks to Jerry McKamy and Angela Chambers at the NNSA and Lee Mason and Don Palac at NASA for their support and guidance. For the authors and multitude of staff that performed this work, the passion for space nuclear reactors was the key to making this experiment a reality.
99 GENERAL AND MISCELLANEOUS↗
Impact of galactic cosmic ray simulation on nutritional content of foods
Foods packaged for future deep-space exploration missions may be prepositioned ahead of astronaut arrival, and will be exposed to galactic cosmic rays (GCRs) and solar radiation in deep space at higher levels and different spectrums than those found in low-Earth orbit (LEO). In this study, we have evaluated the impact of a GCR simulation (approximately 0.5 and 5 Gy doses) at the NASA Space Radiation Laboratory (NSRL) on two retort thermostabilized food products that are good sources of radiation labile nutrients (thiamin, vitamin E, or unsaturated fats). No trends or nutritional differences were found between the radiation-treated samples and the control immediately after treatment or one-year after treatment. Small changes in a few nutrients were measured following one-year of storage. Further studies are needed to confirm these results, as the foods in this study were heterogeneous, and this may have masked meaningful changes due to pouch-to-pouch variations.
59 BASIC BIOLOGICAL SCIENCES↗
CubeSat Interplanetary Exploration: A Deep Dive into Nuclear Propulsion and Astrodynamics for Small Satellites
CubeSats are small satellites most commonly used by universities, however, nowadays places like NASA are looking to CubeSats for interplanetary missions. Because of their universal form fit it makes them cost effective, economical, and therefor desirable for deep space. To achieve deep space exploration, we must explore the applications of propulsion and astrodynamics on small satellites. This paper will touch on one scaling Ion and chemical propulsion as well as nuclear kilo reactors. Two choreographing a flight path for these small satellites and lastly designing an efficient cost-effective platform for CubeSats to get to deep space territory.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Phase Relationships in the Carbon–Titanium–Uranium System for Ultra-High Temperature Nuclear Fuels
Carbides of uranium have attracted interest as fuels for nuclear thermal propulsion (NTP) to drive deep-space exploration owing to their attractive thermal and neutronic properties. Optimization of NTP technology, however, requires ultra-high temperature reactor environments to maximize the ratio of thrust to propellant to achieve peak rocket engine efficiency. Incorporation of transition metals into uranium carbides offers a pathway to increase the melting point of carbide fuels to address the operational challenges posed by NTP. Here, a thermodynamic model has been developed to examine the phase relationships in the C–Ti–U system at NTP conditions. Calculated phase relationships at ultra-high temperatures predict a stable (U, Ti)C solid solution. Additionally, experimental work on C–Ti–U synthesis via arc melting has been carried out, providing data on phase constitution and compositions that can be used to further refine the thermodynamic model that has been developed.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Analysis of neptunium oxides produced through modified direct denitration
Production of neptunium-237 ( 237 Np) target materials for plutonium-238 ( 238 Pu) radioisotope thermoelectric generators (RTGs) for deep space exploration requires advanced chemistry and engineering development. Currently, the domestic Pu-238 Supply Program at Oak Ridge National Laboratory produces neptunium dioxide (NpO 2 ) for target material using a modified direct denitration (MDD) flowsheet. Although the chemistry, reaction mechanisms, and product characteristics of MDD are well understood for uranium, corresponding studies of the neptunium system are still needed to continue optimization of target material properties, production equipment design, and production flowsheets. Here, the objective of this work is to characterize crystalline phases, morphology, surface texture, and particle size of NpO 2 produced via MDD reactions. Solid-phase characterization techniques, including powder X-ray diffraction (pXRD) and scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDS), were employed to achieve this objective. Subsequent data processing using the Morphological Analysis for Material Attribution (MAMA) software was performed to analyze particle morphology and size. Broadly, the powders were found to contain a mixture of NpO 2 and Np 2 O 5 after denitration with a variety of morphologies. After high-firing, the product was found to be NpO 2 with a typical polycrystalline oxide morphology and a grain size ranging from 0.72 to 0.94 µm. These analyses provide knowledge on the reaction pathway for a non-traditional NpO 2 synthesis method and offer additional unique insight into production-scale environments for transuranic materials.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Extreme Temperature Cryptography Based On Nitrogen-Incorporated Ultrananocrystalline Diamond
Physical entropy sources that remain stable under extreme temperatures are essential for cryptography in emerging technological frontiers in deep space exploration, geothermal energy harvesting, and nuclear energy. However, conventional semiconductor platforms fail to generate stable and reliable cryptographic keys above 200 degrees C due to performance degradation. Here, we report a diamond-based cryptographic primitive that exploits the defect-rich sp 2 -bonded grain boundary network in nitrogen-incorporated ultrananocrystalline diamond (n-UNCD) film as a robust entropy source to generate cryptographic keys that remain operationally stable even after enduring extreme temperatures of 700 degrees C for 54 h while also surviving thermal cycling between room temperature and 700 degrees C for 48 h. The strength of the generated keys is assessed through several cryptographic metrics such as bit uniformity, entropy, hamming distances, and correlation coefficients, all of which are found to be near their respective ideal values. Moreover, the generated keys pass the NIST SP 800 and SP 800-90B tests and are also resilient to supply bias variations and a regression-based machine learning attack model based on the Fourier series. The robustness of the keys is attributed to the better thermal stability and chemical inertness of the n-UNCD film. This is supported by high-resolution energy-dispersive X-ray spectroscopy (EDS), which shows no significant lateral diffusion of metal atoms into the n-UNCD layer, and by Raman spectroscopy, which reveals no significant changes in the bonding configuration of the n-UNCD structure. Our findings highlight the remarkable potential of n-UNCD film for extreme environment cryptography by expanding the operational limits of conventional hardware security platforms.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Superelasticity and cryogenic linear shape memory effects of CaFe 2 As 2
Shape memory materials have the ability to recover their original shape after a significant amount of deformation when they are subjected to certain stimuli, for instance, heat or magnetic fields. But, their performance is often limited by the energetics and geometry of the martensitic-austenitic phase transformation. We report a unique shape memory behavior in CaFe 2 As 2 , which exhibits superelasticity with over 13% recoverable strain, over 3 GPa yield strength, repeatable stress–strain response even at the micrometer scale, and cryogenic linear shape memory effects near 50 K. These properties are acheived through a reversible uni-axial phase transformation mechanism, the tetragonal/orthorhombic-to-collapsed-tetragonal phase transformation. These results offer the possibility of developing cryogenic linear actuation technologies with a high precision and high actuation power per unit volume for deep space exploration, and more broadly, suggest a mechanistic path to a class of shape memory materials, ThCr 2 Si 2 -structured intermetallic compounds.
36 MATERIALS SCIENCE↗
Improvement in thermoelectric power factor of mechanically alloyed p-type SiGe by incorporation of TiB{sub 2}
Nearly 60% of the world’s useful energy is wasted as heat and recovering a fraction of this waste heat by converting it as useful electrical power is an important area of research{sup [1]}. Thermoelectric power generators (TEG) are solid state devices which converts heat into electricity. TEG consists of n and p-type thermoelements connected electrically in series and thermally in parallel{sup [2]}. Silicon germanium (SiGe) alloy is one of the conventional high temperature thermoelectric materials and is being used in radio-isotopes based thermoelectric power generators for deep space exploration programs.Temperature (T) dependence of thermoelectric (TE) properties of p-type SiGe and p-type SiGe-x wt.%TiB{sub 2} (x=6,8,10%) nanocomposite materials has been studied with in the temperature range of 300 K to 1100 K. It is observed that there is an improvement in the power factor (α{sup 2}/ρ) of SiGe alloy on addition of TiB{sub 2} upto 8 wt.% that is mainly due to increase in the Seebeck coefficient (α) and electrical conductivity (σ) of the alloy.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
Effects of a refractory metal protective barrier on uranium carbonitride ceramic–metallic composites exposed to a high temperature hydrogen environment
Uranium nitride has been under consideration at NASA and the Department of Energy for nuclear thermal propulsion applications intended for deep space exploration vehicles. It is critical to the success of the technology development that the behavior of the fuel system is properly characterized in operational environments. This body of work fabricated ceramic metal composites consisting of uranium ceramic fuel in a molybdenum and molybdenum–tungsten metal matrix, both with and without an exterior molybdenum barrier. Specimens were introduced to a high temperature hydrogen environment and characterized through x-ray diffraction, scanning electron microscopy, and energy dispersive spectroscopy to identify characteristic changes. A portion of the specimens was fabricated with a 1.27 mm thick molybdenum barrier in order to isolate the material from the hydrogen environment. Instability of the uranium nitride occurred as low as 2073 K, leading to aggressive instability approaching 2658 K. Carbon reactions with the metal matrix were observed as well as alloying between the uranium and metal matrix constituents. The liquid uranium resulting from the instability of the uranium nitride was observed to attack the grain boundaries of the refractory metal, resulting in the formation of a liquid uranium molybdenum eutectic melt. Specimens encased in a barrier experienced similar results. The authors conclude this is a significant challenge to applications of this cermet at these temperatures. Alternate configurations with resilient hermetic seals or lower temperature applications such as power reactors may have more success.
36 MATERIALS SCIENCE↗
Kilopower Reactor Using Stirling TechnologY (KRUSTY) Component Critical Experiments
A series of critical experiments were conducted at the National Criticality Experiments Research Center (NCERC) in Nevada to evaluate the operational performance of a compact reactor that eventually will resemble the flight unit the National Aeronautics and Space Administration will use for deep space exploration. The results from the experiments are compared to preliminary results from computational models using MCNP and ENDF/B-7.1 neutron cross-section data.
73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
Quantitative Particle Analysis of Neptunium-237 Oxides: Optimization of MAMA Analysis for Modified Direct Denitration Products
The production of plutonium-238 through irradiation of neptunium-237 ( 237 Np) target materials for the use in radioisotope thermoelectric generators is paramount for continued deep space exploration. This work employs scanning electron microscopy to analyze 237 Np materials coupled with a well-developed image analysis framework (Morphological Analysis for Material Attribution, or MAMA) to determine the degree of micron-scale homogeneity in the materials. This work demonstrated how the quantification of particle characteristics can validate production materials and affirm the qualitative similarities observed in micrographs. The 237 Np oxide particle analysis determined that the materials from five production runs were quantitatively homogenous (significant at α = 0.05) in particle area, circularity, equivalent circular diameter, and ellipse aspect ratio, with two of the sampling dates having statistically significant different means for one of the four characteristics. Furthermore, these metrics not only confirm general homogeneity of the material but also expand the application of MAMA workflows to 237 Np materials, demonstrating the utility of MAMA analysis for a wider breadth of nuclear materials than previously reported. In the open literature, this study is the first time that these microanalytical techniques were applied to 237 Np materials to this degree.
MAMA↗
Kilowatt Reactor Using Stirling TechnologY (KRUSTY) Demonstration. CEDT Phase 1 Preliminary Design Documentation
The intent of the integral experiment request IER 299 (called KiloPower by NASA) is to assemble and evaluate the operational performance of a compact reactor configuration that closely resembles the flight unit to be used by NASA to execute a deep space exploration mission. The reactor design will include heat pipes coupled to Stirling engines to demonstrate how one can generate electricity when extracting energy from a “nuclear generated” heat source. This series of experiments is a larger scale follow up to the DUFF series of experiments1,2 that were performed using the Flat-Top assembly.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗