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NASA NTRS2018

Needs and Opportunities in the Development of Advanced Materials and Manufacturing Methods for Future Long-Duration Human Space Exploration

Weight, functionality, and sustainability are all critical concerns for future, long-duration, human exploration of space. Exploration missions will be mass-limited, since the amount of supplies and instruments that future astronauts will be able to take with them will be limited by launch vehicle and spacecraft mass and efficiency. Astronauts will need to have the capability to repair or replace worn-out or broke hardware and produce new components to be able to function for long periods at locations far-removed from Earth. Ultra-lightweight, multifunctional materials will be required to enable significant reductions in launch vehicle, spacecraft, and habitat mass in order to maximize payload. "Mass-less Exploration" concepts must be developed that will recycle materials and waste and convert available planetary materials into new feedstock materials and utilize in-space additive manufacturing to use these materials to produce the

composites↗

NASA NTRS1994

Advanced Life Support Systems: Opportunities for Technology Transfer

NASA's future missions to explore the solar system will be of long-duration possibly lasting years at a time. Human life support systems will have to operate with very high reliability for these long periods with essentially no resupply from Earth. Such life support systems will make extensive use of higher plants, microorganisms, and physicochemical processes for recycling air and water, processing wastes, and producing food. Development of regenerative life support systems will be a pivotal capability for NASA's future human missions. A fully functional closed loop human life support system currently does not exist and thus represents a major technical challenge for space exploration. Technologies where all life support consumables are recycled have many potential terrestrial applications as well. Potential applications include providing human habitation in hostile environments such as the polar regions or the desert in such a way as to minimize energy expenditures and to minimize negative impacts on those often ecologically-sensitive areas. Other potential applications include production of food and ornamental crops without damaging the environment from fertilizers that contaminate water supplies; removal of trace gas contaminants from tightly sealed, energy-efficient buildings (the so-called sick building syndrome); and even the potential of gaining insight into the dynamics of the Earth's biosphere such that we can better manage our global environment. Two specific advanced life support technologies being developed by NASA, with potential terrestrial application, are the zeoponic plant growth system and the Hybrid Regenerative Water Recovery System (HRWRS). The potential applications for these candidate dual use technologies are quite different as are the mechanisms for transfer. In the case of zeoponics, a variety of commercial applications has been suggested which represent potentially lucrative markets. Also, the patented nature of this product offers opportunities for licensing to commercial entities. In the case of the HRWRS, commercial markets with broad applications have not been identified but some terrestrial applications are being explored where this approach has advantages over other methods of waste water processing. Although these potential applications do not appear to have the same broad attraction from the standpoint of rapid commercialization, they represent niches where commercialization possibilities as well as social benefits could be realized.

Fields, B.↗

NASA NTRS1979

Automated Array Assembly Task In-depth Study of Silicon Wafer Surface Texturizing

Several aspects of silicon wafer surface texturizing were studied. A low cost cleaning method that utilizes recycled Freon in an ultrasonic vapor degreaser to remove organic and inorganic contaminants from the surface of silicon wafers as received from silicon suppliers was investigated. The use of clean dry air and high throughout wafer batch drying techniques was shown to lower the cost of wafer drying. A two stage texturizing process was examined for suitability in large scale production. Also, an in-depth gettering study with the two stage texturizing process was performed for the enhancement of solar cell efficiency, minimization of current versus voltage curve dispersion, and improvement in process reproducibility. The 10% efficiency improvement goal was exceeded for the near term implementation of flat plate photovoltaic cost reduction.

Jones, G. T.↗

NASA NTRS1982

Some tradeoffs in ingot shaping and price of solar photovoltaic modules

Growth of round ingots is cost-effective for sheets but leaves unused space when round cells are packed into a module. This reduces the packing efficiency, which approaches 95% for square cells, to about 78% and reduces the conversion efficiency of the module by the same ratio. Shaping these ingots into squares with regrowth of cut silicon improves the packing factor, but increases growth cost. The cost impact on solar cell modules was determined by considering shaping ingots in stages from full round to complete square. The sequence of module production with relevant price allocation guidelines is outlined. The severe penalties in add-on price due to increasing slice thickness and kerf are presented. Trade-offs between advantages of recycling silicon and shaping costs are developed for different slicing scenarios. It is shown that shaping results in cost saving of up to 21% for a 15 cm dia. ingot.

Daud, T.↗

NASA NTRS1992

Scenarios for optimizing potato productivity in a lunar CELSS

The use of controlled ecological life support system (CELSS) in the development and growth of large-scale bases on the Moon will reduce the expense of supplying life support materials from Earth. Such systems would use plants to produce food and oxygen, remove carbon dioxide, and recycle water and minerals. In a lunar CELSS, several factors are likely to be limiting to plant productivity, including the availability of growing area, electrical power, and lamp/ballast weight for lighting systems. Several management scenarios are outlined in this discussion for the production of potatoes based on their response to irradiance, photoperiod, and carbon dioxide concentration. Management scenarios that use 12-hr photoperiods, high carbon dioxide concentrations, and movable lamp banks to alternately irradiate halves of the growing area appear to be the most efficient in terms of growing area, electrical power, and lamp weights. However, the optimal scenario will be dependent upon the relative 'costs' of each factor.

Wheeler, R. M.↗

NASA NTRSDate not supplied

Characterizing Electrical Arc Behavior in Ion Engines

Gridded ion engines represent a class of electric thrusters characterized by high propulsive efficiency and high total impulse capabilities. These engines operate by applying high voltage to multi-aperture electrodes, thereby electrostatically accelerating plasma to generate thrust. Within the course of normal operations, periodic occurrences of high voltage breakdowns manifest within the thruster. These breakdowns constitute an inherent aspect of operation, with observations indicating a diminishing frequency and total count over the thruster's operational lifespan. To safeguard the propulsion system during such occurrences, the power processing unit (PPU) employs an automated arc extinction sequence, termed "recycle," which is triggered upon detection of an over-current condition. The initial phase of this sequence involves momentarily deactivating the high voltage and reducing the discharge current to a predetermined level, minimizing plasma impingement as the ion beam is defocused. The high voltage is subsequently reapplied, and the discharge current is returned to its nominal value. The entire sequence typically spans approximately 800 milliseconds. Throughout a recycle event, the propulsion system experiences various current and voltage transients as the arc current traverses the system and different power supplies are toggled on and off.

electric propulsion↗

NASA NTRSDate not supplied

Benefits of Trash-to-Gas Versus Jettison of Waste Via Trash-Lock for Mars Transit

Human exploration missions to Mars pose difficulties due to the significant waste that will be generated during transit, which will need to be carried along or disposed of in some fashion. Waste removal from the spacecraft decreases the spacecraft’s mass as well as the associated logistic items necessary for storing the waste. A mission propellant analysis was performed to highlight the mass benefits that may be accessed via waste removal. The propellant mass savings were determined for different waste removal rates (2.9 – 11.6 kg/day) with the highest removal rate leading to the greatest propellant savings of 7,785 kg for an 850-day round-trip mission. Due to these benefits, two methods for waste reduction were studied for the 850-day Mars mission: Trash-to-Gas (TtG) and physical jettison via a trash-lock. The trash-to-gas methods considered were combustion, steam reforming, and pyrolysis, which convert waste into ventable gases (e.g., CO2, CO, CH4, etc.). Combustion and steam reforming require a co-reactant (O2 and/or H2O). Therefore, additional processing units or integration with the spacecraft’s environmental control and life support system (ECLSS) are required to facilitate recycle of the pertinent species. In contrast, pyrolysis is a purely thermal degradation process, which can operate as a standalone system; however, a lower percentage of waste is gasified with pyrolysis. The study herein compares standalone TtG (e.g., Advanced Organic Waste Gasifier, Plasma Pyrolysis, etc.), integrated TtG-ECLSS (e.g., Orbital Syngas Commodity Augmentation Reactor, Incineration/Gasification, etc.), and physical jettison. Each system’s mass, volume, power, and cooling requirements were compared via an equivalent system mass (ESM) analysis to ascertain potentially promising technologies that can achieve efficient waste removal while minimizing their own spacecraft load. This study highlights the advantages and disadvantages of the different waste management technologies and provides recommendations on the promising technologies based on the ESM metric and propellant mass savings.

Jettison↗

NASA NTRS2010

Life Support with Failures and Variable Supply

The life support system for long duration missions will recycle oxygen and water to reduce the material resupply mass from Earth. The impact of life support failures was investigated by dynamic simulation of a lunar outpost habitat life support model. The model was modified to simulate resupply delays, power failures, recycling system failures, and storage failures. Many failures impact the lunar outpost water supply directly or indirectly, depending on the water balance and water storage. Failure effects on the water supply are reduced if Extra Vehicular Activity (EVA) water use is low and the water supply is ample. Additional oxygen can be supplied by scavenging unused propellant or by production from regolith, but the amounts obtained can vary significantly. The requirements for oxygen and water can also vary significantly, especially for EVA. Providing storage buffers can improve efficiency and reliability, and minimize the chance of supply failing to meet demand. Life support failures and supply variations can be survivable if effective solutions are provided by the system design

Jones, Harry↗

NASA NTRS2003

Fuel cell environmental life cycle assessment : a progress report

Energy generation using fuel cells offers the possibility of high conversion efficiency and reduced pollution. Thus, in the futue, conventional methods of energy generation using coalfired power plants, natural gas turbines and internal combustion engines can potentially be replaced by fuel cells. The United States, Japan and several countries in Europe are currently developing fuel cells for transportation, distributed energy generation and portable electronics applications. On a system basis, the efficiency of chemical to electrical energy conversion in fuel cells can be as high as 45%. Also, because of the lower operating temperatures compared to turbines and internal combustion engines, emissions such as carbon monoxide and nitrogen oxides are extremely small. An assessment of the environmental impact of fuel cells over the entire lifecycle is needed to determine the specific benefits in various application scenarios. Such a comparative pollutants assessment must include a "cradle to grave" approach encompassing fuel production, fuel transportation, materials/manufacturing processes, waste management, and recycling. A comparative pollutant model would be a useful tool for industry and government in estimating energy savings and environmental credits, and providing a holistic understanding on regulatory needs. Another important benefit would be the ability to make appropriate comparisons with competitive energy generation technologies such as hybrids, turbines, and internal combustion engines, and to set up realistic targets. Also, exercising the model will assist in the initial screening for potential hot spots and showstoppers and focus on the right component technologies design for manufacturing, designs for input substitution and waste minimization, and prevent any unforeseen burdens.

Narayanan, S. R.↗

NASA NTRS1993

Microscale characterization of dissolved organic matter production and uptake in marine microbial mat communities

Intertidal marine microbial mats exhibited biologically mediated uptake of low molecular weight dissolved organic matter (DOM), including D-glucose, acetate, and an L-amino acid mixture at trace concentrations. Uptake of all compounds occurred in darkness, but was frequently enhanced under natural illumination. The photosystem 2 inhibitor, 3-(3,4-dichlorophenyl)-1,1-dimethyl urea (DCMU) generally failed to inhibit light-stimulated DOM uptake. Occasionally, light plus DCMU-amended treatments led to uptake rates higher than light-incubated samples, possibly due to phototrophic bacteria present in subsurface anoxic layers. Uptake was similar with either 3H- or 14C-labeled substrates, indicating that recycling of labeled CO2 via photosynthetic fixation was not interfering with measurements of light-stimulated DOM uptake. Microautoradiographs showed a variety of pigmented and nonpigmented bacteria and, to a lesser extent, cyanobacteria and eucaryotic microalgae involved in light-mediated DOM uptake. Light-stimulated DOM uptake was often observed in bacteria associated with sheaths and mucilage surrounding filamentous cyanobacteria, revealing a close association of organisms taking up DOM with photoautotrophic members of the mat community. The capacity for dark- and light-mediated heterotrophy, coupled to efficient retention of fixed carbon in the mat community, may help optimize net production and accretion of mats, even in oligotrophic waters.

NASA Discipline Exobiology↗

NASA NTRS2001

Residue detection for real-time removal of paint from metallic surfaces

Paint stripping from large steel ships and other metallic surfaces is a major issue in the maintenance and refurbishing of structures, and environmental concerns are greatly limiting the possible options. As a result, waterjet with water recycling has become the leading form of paint stripping and robotic manipulators with scanning bridges were constructed by various manufacturers to address this need. The application of such scanning bridges is slow and their access is constrained by the complex shape of the ship hull and various features on the surface. To overcome these limitations, a robotic system that is called Ultrastrip (UltraStrip Systems, Inc., Stuart, FL) is developed. This system uses magnetic wheels to attach the stripper to the structure and travel on it while performing paint stripping. To assure efficient paint stripping feedback data is required to control the travel speed by monitoring the paint thickness before and during the stripping process. Efforts at JPL are currently underway to develop the required feedback capability to assure effective paint stripping. Various possible sensors were considered and issues that can affect the sensitivity, reliability and applicability of the sensors are being investigated with emphasis on measuring the initial conditions of the paint. Issues that affect the sensory data in dynamic conditions are addressed while providing real-time real feedback for the control of the paint stripper speed of travel.

NDT↗

NASA NTRS2011

Compact and Lightweight Sabatier Reactor for Carbon Dioxide Reduction

The utilization of CO2 to produce life support consumables, such as O2 and H2O, via the Sabatier reaction is an important aspect of NASA s cabin Atmosphere Revitalization System and In-Situ Resource Utilization architectures for both low-earth orbit and long-term manned space missions. In the current International Space Station (ISS) and other low orbit missions, metabolically-generated CO2 is removed from the cabin air and vented into space, resulting in a net loss of O2. This requires a continuous resupply of O2 via water electrolysis, and thus highlights the need for large water storage capacity. For long-duration space missions, the amount of life support consumables is limited and resupply options are practically nonexistent, thus atmosphere resource management and recycle becomes crucial to significantly reduce necessary O2 and H2O storage. Additionally, the potential use of the Martian CO2-rich atmosphere and Lunar regolith to generate life support consumables and propellant fuels is of interest to NASA. Precision Combustion, Inc. (PCI) has developed a compact, lightweight Microlith(Registered TradeMark)-based Sabatier (CO2 methanation) reactor which demonstrates the capability of achieving high CO2 conversion and near 100% CH4 selectivity at space velocities of 30,000-60,000 hr-1. The combination of the Microlith(Registered TradeMark) substrates and durable, novel catalyst coating permitted efficient Sabatier reactor operation that favors high reactant conversion, high selectivity, and long-term durability. This paper presents the reactor development and performance results at various operating conditions. Additionally, results from 100-hr durability tests and mechanical vibration tests are discussed.

Junaedi, Christian↗

NASA NTRS2019

Long Term Biological Treatment of Space Habitation Waste Waters in a One Stage MABR: Comparison of Operation for N and C Oxidation With and Without Simultaneous Denitrification

Aerobic biological stabilization has been previously demonstrated for full size MABR?s (CoMANDR 1.0, CoMANDR 2.0, and R-CoMANDR) over operating periods of ~1 year. These systems have successfully treated a variety of possible habitation waste streams including an ISS (urine + flush and humidity condensate) and Early Planetary Base (EPB) wastewater (urine, flush water, hygiene wastewater, and laundry). Biological stabilization has a number of advantages including: 1) elimination of hazardous pre-treat chemicals; 2) production of NOx species (that can be easily rejected by evaporative or membrane systems); 3) elimination of volatile organic constituents; 4) a low pH effluent that facilitates membrane and distillation processes; and 5) a effluent that produces a better quality and less hazardous brine for water recovery. Previous work has primarily evaluated aerobic operation in which organic carbon and nitrogen is converted to CO2 and NOx-, respectively. An alternative to aerobic operation would be to include anoxic operation to promote denitrification and production of N2 gas. This allows for production of make-up gas as well as reduces the O2 demand and can increase ammonia oxidation efficiency. We evaluated the operation of a full scale (2 crew/day) MABR operated to perform oxidation of organic carbon and nitrogen with and without simultaneous reduction of oxidized N to N2 gas, simultaneous nitrification denitrification (SNDN). The system was challenged with a variety of space habitation wastewaters ranging from an ISS composition to a possible EPB waste stream under both continuous and on-production feeding modes. The system has been operated for over 2.5 years. We report on an overall comparison of aerobic oxidation and SNDN operational regimes to evaluate the system with the best overall attributes to support recycling of space habitation waste streams.

Biological water processing↗

NASA NTRS1987

Vapor Compression Distillation Subsystem (VCDS) component enhancement, testing and expert fault diagnostics development, volume 1

Vapor compression distillation technology for phase change recovery of potable water from wastewater has evolved as a technically mature approach for use aboard the Space Station. A program to parametrically test an advanced preprototype Vapor Compression Distillation Subsystem (VCDS) was completed during 1985 and 1986. In parallel with parametric testing, a hardware improvement program was initiated to test the feasibility of incorporating several key improvements into the advanced preprototype VCDS following initial parametric tests. Specific areas of improvement included long-life, self-lubricated bearings, a lightweight, highly-efficient compressor, and a long-life magnetic drive. With the exception of the self-lubricated bearings, these improvements are incorporated. The advanced preprototype VCDS was designed to reclaim 95 percent of the available wastewater at a nominal water recovery rate of 1.36 kg/h achieved at a solids concentration of 2.3 percent and 308 K condenser temperature. While this performance was maintained for the initial testing, a 300 percent improvement in water production rate with a corresponding lower specific energy was achieved following incorporation of the improvements. Testing involved the characterization of key VCDS performance factors as a function of recycle loop solids concentration, distillation unit temperature and fluids pump speed. The objective of this effort was to expand the VCDS data base to enable defining optimum performance characteristics for flight hardware development.

Kovach, L. S.↗

NASA NTRS2011

Evaluation of Bosch-Based Systems Using Non-Traditional Catalysts at Reduced Temperatures

Oxygen and water resupply make open loop atmosphere revitalization (AR) systems unfavorable for long-term missions beyond low Earth orbit. Crucial to closing the AR loop are carbon dioxide reduction systems with low mass and volume, minimal power requirements, and minimal consumables. For this purpose, NASA is exploring using Bosch-based systems. The Bosch process is favorable over state-of-the-art Sabatier-based processes due to complete loop closure. However, traditional operation of the Bosch required high reaction temperatures, high recycle rates, and significant consumables in the form of catalyst resupply due to carbon fouling. A number of configurations have been proposed for next-generation Bosch systems. First, alternative catalysts (catalysts other than steel wool) can be used in a traditional single-stage Bosch reactor to improve reaction kinetics and increase carbon packing density. Second, the Bosch reactor may be split into separate stages wherein the first reactor stage is dedicated to carbon monoxide and water formation via the reverse water-gas shift reaction and the second reactor stage is dedicated to carbon formation. A series system will enable maximum efficiency of both steps of the Bosch reaction, resulting in optimized operation and maximum carbon formation rate. This paper details the results of testing of both single-stage and two-stage Bosch systems with alternative catalysts at reduced temperatures. These results are compared to a traditional Bosch system operated with a steel wool catalyst.

Abney, Morgan B.↗

NASA NTRS1991

Oxygen extraction from lunar soil by fluorination

Mining and processing of lunar material could possibly lead to more cost-efficient scenarios for permanent presence of man in space and on the Moon. Production of oxygen for use as propellant seems especially important. Different candidate processes for oxygen-extraction from lunar soil were proposed, of which the reduction of ilmenite by hydrogen was studied most. This process, however, needs the concentration of ilmenite from lunar regolith to a large extent and releases oxygen only with low efficiency. Another possibility - the fluorination method - which works with lunar bulk material as feedstock is discussed. Liberation of oxygen from silicate or oxide materials by fluorination methods has been applied in geoscience since the early sixties. The fact that even at moderate temperatures 98 to 100 percent yields can be attained, suggests that fluorination of lunar regolith could be an effective way of propellant production. Lunar soil contains about 50 percent oxygen by weight which is gained nearly completely through this process as O2 gas. The second-most element Si is liberated as gaseous SiF4. It could be used for production of Si-metal and fluorine-recycling. All other main elements of lunar soil will be converted into solid fluorides which also can be used for metal-production and fluorine-recycling. Preliminary results of small scale experiments with different materials are discussed, giving information on specific oxygen-yields and amounts of by-products as functions of temperature. These experiments were performed with an already existing fluorine extraction and collection device at the University of Bonn, normally used for determination of oxygen-isotopic abundances. Optimum conditions, especially concerning energy consumption, are investigated. Extrapolation of the experimental results to large industrial-type plants on the Moon is tried and seems to be promising at first sight. The recycling of the fluorine is, however, crucial for the process. It might be achieved by means of electrolysis. This needs further investigation. The technical problem of transport and handling of the toxic and corrosive fluorine seems to be solvable and could be done by inert storage vessels.

Seboldt, W.↗

NASA NTRS2004

Warm Rain Processes Over the Tropical Oceans and Implications on Climate Change

In this talk, we will first show results from TRMM regarding the characteristics of warm rains over the tropical oceans, and the dependence of rate of warm rain production on sea surface temperature. Results lead to the hypothesis that warm rain production efficiency, i.e., autoconversion, may be increased in a warm climate. We use the GEOS-II GCM to test this hypothesis. Our modeling results show that in a climate with increased rate of autoconversion, the total rain amount is increased, with warm rain contributing to a larger portion of the increase. The abundant rainout of warm precipitation at middle to low levels causes a reduction of high cloud cover due to the depletion of water available for ice-phase rain production. As a result, more isolated, but more intense penetrative convection develops. Results also show that increased autoconversion reduces the convective adjustment time scale tends, implying a faster recycling of atmospheric water. Most interestingly, the increased low level heating associated with warm rain leads to more energetic Madden and Julian oscillations in the tropics, with well-defined eastward propagation. While reducing the autoconversion leads to an abundant mix of westward and eastward tropical disturbance on daily to weekly time scales. The causes of the sensitivity of the dynamical regimes to the microphysics parameterization in the GCM will be discussed.

Lau, William K. M.↗

NASA NTRSDate not supplied

ISS Wastewater Pretreatment via DNA Pattern Picofilter Using Inorganic Brine Stimulant

Astronauts in the International Space Station (ISS) need as much water as they can access, whether it comes from people's breath, sweat or urine, recycled shower water or hand washing. It is of vital importance that any type of water is recycled and filtrated through different methods so it can be re-used. Recently, Cerahelix Inc. offered a ceramic tubular membrane element that uses DNA strands as a pattern in a sol-gel process that allows the sintered product to have a pore size in the picometer scale and claims to achieve ten times higher purity than other commercially available ceramic filters. This should allow higher purities and yields at reduced energy costs and theoretically allow near total dewatering of the reject stream and greater than 80% removal of polyvalent ions. Trials were performed with Cerahelix Inc. filters using an inorganic brine simulant at two pHs to test the efficiency of Pico Helix TM membranes and determine their feasibility for spacecraft wastewater treatment processes. Emphasis was placed on the polyvalent ions: SO42-, PO43-, Mg2+, and Ca2+. These ions should be rejected almost entirely from the feed solution and, not permeate through the filter. Results show that at a pH of 4.2, permeation of the polyvalent ions varied from 59% to 74% and at pH of 8.0, permeation varied from 72% to 87%. An Extended Nernst Planck (ENP) approach that describes the mass transfer process for a pico-filtration membrane was used to construct a model to inform the experimental expectations and outcome.

Carolina Franco↗