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Hydrofluoroether (HFE) Cleaning Fluid Replacement and Qualification

This NASA Engineering and Safety Center (NESC) Technical Assessment Report addresses the urgent need to identify, test, and qualify replacement cleaning solvents and technologies following 3M’s decision to discontinue production of hydrofluoroether (HFE) products, including Novec HFE-7100, by the end of 2025. HFE-7100 is widely used across NASA for precision cleaning of ground and flight hardware, especially in oxygen system components, and as a heat transfer fluid in high-power-density thermal control systems. The assessment evaluates commercially available replacement solvents, alternative cleaning technologies, and their compatibility with NASA’s operational requirements. Key findings include the identification of viable solvent replacements, their performance in contaminant removal, materials compatibility, and oxygen system safety. The report also explores novel cleaning approaches, including aqueous, supercritical CO₂, cryogenic aerosol, plasma, UV-ozone, magnetically optimized fluids, and induced charge active filtration, highlighting their merits, limitations, and readiness for NASA adoption. The NESC provides recommendations for solvent selection, facility adaptation, and continued technology maturation to ensure mission continuity and regulatory compliance.

Alternative Cleaning Technologies↗

A Group Increment Scheme for Infrared Absorption Intensities of Greenhouse Gases

A molecule's absorption in the atmospheric infrared (IR) window (IRW) is an indicator of its efficiency as a greenhouse gas. A model for estimating the absorption of a fluorinated molecule within the IRW was developed to assess its radiative impact. This model will be useful in comparing different hydrofluorocarbons and hydrofluoroethers contribution to global warming. The absorption of radiation by greenhouse gases, in particular hydrofluoroethers and hydrofluorocarbons, was investigated using ab initio quantum mechanical methods. Least squares regression techniques were used to create a model based on this data. The placement and number of fluorines in the molecule were found to affect the absorption in the IR window and were incorporated into the model. Several group increment models are discussed. An additive model based on one-carbon groups is found to work satisfactorily in predicting the ab initio calculated vibrational intensities.

Kokkila, Sara I.↗

HFE 7100 Compatibility with Orbiter Materials

Chlorofluorocarbon (CFC) 113 is currently specified as the precision cleaning and verification fluid for orbiter materials. The production ban of CFC 113, an ozone-depleting chlorofluorocarbon, has resulted in a search for a replacement cleaning fluid. Recently, the 3M Company announced the manufacture of a new class of cleaning fluids, hydrofluoroethers. The first in this class of cleaning fluids is HFE 7100, perfluorobutyl methyl ether. This cleaning fluid has been submitted for consideration as a replacement for CFC 113. One of the requirements of the certification process for a replacement cleaning fluid is compatibility testing. The Johnson Space Center (JSC) Materials and Manufacturing Division has requested that NASA JSC White Sands Test Facility perform the compatibility testing with HFE 7100 on selected orbiter materials. Most of the materials selected for testing were previously evaluated for compatibility with CFC 113. Some of the materials are new additions to the orbiter or were not available when the compatibility testing was performed with CFC 113. These materials were evaluated with both cleaning fluids and the results were used to compare the response to the cleaning fluid and to satisfy the certification process requirements. It was found that HFE 7100 is generally compatible with the materials tested.

Chlorofluorocarbon↗

Evaluation of HFC 245ca and HFC 236ea as foam blowing agents

Hydrochlorofluorocarbon (HCFC) 141b has been selected as the interim blowing agent for use in urethane insulations on NASA's Space Shuttle External Tank. Due to the expected limited commercial lifetime of this material, research efforts at the NASA Thermal Protection Systems Materials Research Laboratory at the Marshall Space Flight Center are now being devoted to the identification and development of alternatives with zero ozone depletion potential. Physical blowing agents identified to date have included hydrocarbons, fluorocarbons, hydrofluoroethers, and more predominantly, hydrofluorocarbons (HFCs). The majority of the HFC evaluations in industry have focused on the more readily available, low boiling candidates such as HFC 134a. Higher boiling HFC candidates that could be handled at ambient conditions and use current processing equipment would be more desirable. This paper will describe results from a research program of two such candidate HFC's performed as a cooperative effort between Martin Marietta Manned Space Systems, the U.S. Environmental Protection Agency, and Oak Ridge National Laboratories. The purpose of this effort was to perform a cursory evaluation of the developmental HFC's 245ca and 236ea as blowing agents in urethane based insulations. These two materials were selected from screening tests of 37 C2, C3, and C4 isomers based on physical properties, atmospheric lifetime, flammability, estimated toxicity, difficulty of synthesis, suitability for dual use as a refrigerant, and other factors. Solubility of the two materials in typical foam components was tested, pour foaming trials were performed, and preliminary data were gathered regarding foam insulation performance.

Sharpe, Jon↗

Development Testing and Analysis of the Integrated Gateway-ESPRIT Bipropellant Refuelling System

The Gateway will be humanity’s first space station orbiting the Moon completed by NASA in partnership with ESA and other US and international partners. The Gateway will provide critical support to sustainable human exploration on the moon through the Artemis program. To enable the Lunar Gateway to complete its mission, on orbit refuelling is essential. The ESPRIT Refuelling Module (ERM) will provide the capability to transfer propellants, MMH and MON-3, through the Habitation and Logistics Outpost (HALO) to the Power and Propulsion Element (PPE). The transfer of these propellants carries known risks and hazards. These hazards include overpressure of the propellant lines during priming sequences between modules and during refuelling pause operations. To support the early system development and to mitigate these risks, a collaborative test program between NASA, ESA and Thales Alenia Space was completed at the Thales Alenia Space test facility in Harwell, UK. This test program integrated fluidic breadboards of the ERM, HALO and PPE modules. The objectives of the test program were to demonstrate and characterise critical performance and transient operations, inform refuelling concept of operations and to calibrate and validate numerical models of the refuelling subsystem in EcosimPro. To support the completion of this final objective a detailed model of the integrated breadboard was developed in EcosimPro and key steady-state and transient test cases were simulated. As an industry first, a National Institute of Standards and Technology (NIST) database correlation for Hydrofluoroether (HFE-7000) was used as a mixed oxides of nitrogen (MON-3) simulant with EcosimPro and European Space Propulsion System Simulation (ESPSS) libraries to result in a more accurate analysis for transient phenomenon such as priming. The test and simulation data showed good agreement validating the model for further system analysis as the ERM design progresses.

Refuelling↗