Designing a Self-Sterilizing and CO2 Sequestering Surface Coating from an ISRU Perspective
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Engineering topics
Publications and source records attributed to Cheol Park.
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A long-term human space presence is dependent on maintaining a safe living environment. Disinfecting surfaces is essential to protecting astronauts from potential pathogens, as well as structural components of the habitat from damaging biofilms. Developing a surface coating that utilizes readily available light has the potential to provide sterilization with additional functionality. Titanium dioxide (TiO2) is a commonly used photocatalyst owing to its efficiency, economic feasibility, and safety to humans. TiO2 photocatalyst modified with other metals such as copper or iron could allow for self-sterilization, photocatalytic memory, and photoreduction of carbon dioxide (CO2) to fuels on Mars. Sustainable design of the photocatalyst should account for the resources available, specifically within the Martian and Lunar regolith. This project reviews the current technologies to design a TiO2 photocatalyst which can be incorporated into a space habitat’s inner lining.
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Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.
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Extreme space environments such as space vacuum, radiation, jagged lunar dust, microgravity, high thermal excursion, micrometeoroids, thrust plume ejecta, seismic events, and their synergistically-adverse effects make sustainable space exploration extremely challenging. More robust and sustainable advanced materials and structures are needed to protect crew and equipment to extend space missions longer and safer with minimum service and repair needs. Recent progress of NASA efforts on sustainable multifunctional structural materials will be introduced.
With NASA’s Artemis program aiming to establish a human presence on the Moon and eventually on Mars, protecting astronauts from radiation is necessary. Flight-heritage materials, like those with high hydrogen content, such as polyethylene (PE), have proven to be effective radiation shields. This is due to hydrogen’s high charge-to-mass ratio, low secondary radiation production, efficient energy absorption, and high cross-section, which increases the probability of particle interactions to slow or stop ionized particles. Boron nitride nanotubes (BNNTs) and other boron-rich materials offer more effective thermal neutron radiation-stopping capabilities due to their high cross-section and neutron absorption properties. BNNTs also enhance the mechanical properties of radiation shielding material due to their high strength-to-weight ratios. However, integrating high volumes of nanotubes in a matrix without defects presents significant manufacturing challenges. To address this, a bulk nanocomposite laminate fabricating technique, involving synthesizing millimeter-long vertically aligned BNNTs, densifying the nanotubes to high-volume fractions, and infusing the nanotubes with PE while applying heat and pressure was utilized to fabricate the BNNT-PE nanocomposite that was tested for its radiation shielding properties at NASA Langley Research Center’s neutron radiation exposure lab. Results from these experiments will be discussed in the presentation.
Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.
Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.