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Evolution of NASA’s Nuclear Flight Safety Program to Meet Changing Needs

Over the past 4 years, the United States (U.S.) Government has issued several new National policies that fundamentally change the approach to nuclear flight safety for aerospace applications, including the complete revision of the Federal policy for handling launch of spacecraft containing space nuclear systems. In response, the National Aeronautics and Space Administration (NASA) is updating its nuclear flight safety program while still maintaining consistency with other Federal policies, international conventions, and NASA’s own policies. To achieve this evolution, NASA is factoring in an objectives-driven and assurance case mindset to develop a risk-informed and performance-based program. NASA and others have successfully applied this mindset in other disciplines and contexts and it is being pursued here via broad cooperation within NASA and with external stakeholders. This paper will briefly describe how the NASA nuclear flight safety program is evolving to meet these changing needs.

NASA↗

Design Study of a Nuclear-Electric Transport Vehicle for Ice Giant Missions

Nuclear-electric propulsion, in which a nuclear reactor is used to power high specific-impulse ion thrusters for propulsion, is a promising method for such applications as missions to the ice giants Uranus and Neptune, identified as targets of high science value in the most recent NASA Decadal Survey of Planetary Science. Until recently, however, this has required a lightweight space nuclear power system that has yet to be designed. NASA has recently been developing the “Kilopower” nuclear reactor as a power source for future exploration missions, with a 1-kW prototype recently tested under the KRUSTY program. We utilized a next-generation Kilopower reactor to design a transportation system for missions to the ice giant planets. The mission objectives were to carry a payload of 1164 kg, comprising a lander/hopper vehicle to be delivered to explore the moon or moons of the target ice giant, along with atmospheric probes to drop into the atmosphere, plus 188 kg of science instrumentation on the spacecraft itself.

nuclear electric propulsion↗

Nuclear Thermal Propulsion Material Trade for Additively Manufactured Regenerative Chambers

Nuclear thermal propulsion (NTP) is a game changing technology with advantages over chemical propulsion systems for deep space missions but comes with many engineering challenges. This paper focuses on the challenge of material selection for a regeneratively-cooled chamber for use in a nuclear environment with minimal design margins. Chemical compatibility with reactants and products following energy extraction (be it through combustion or neutron bombardment) must be considered. Similarly, mechanical and thermophysical properties (e.g., density, thermal conductivity, yield strength, etc.) as functions of temperature are critical. While hydrogen embrittlement environment (HEE) is a risk and consideration for traditional chemical combustion chambers, application in a nuclear thermal engine adds additional material compatibility and resilience requirements to long-term nuclear radiation exposure. Chamber materials in this trade included, but were not limited to, A-286, Haynes 230, Haynes 282, CRES 347, GRCop-42, GRCop-84, Inconel 625, JBK-75, and NASA HR-1. The material trade focuses on modern additive manufacturing techniques and hypothetical geometric constraints.

Nuclear Thermal Propulsion↗

A Technology Maturation Plan for the Development of Nuclear Electric Propulsion

Over the last two years NASA’s Space Nuclear Propulsion (SNP) Project formulated a Technology Maturation Plan (TMP) for development of the sub-systems needed for a MW-class Nuclear Electric Propulsion (NEP) system which, combined with a high thrust chemical propulsion stage, would be suitable for human missions to Mars. Two recent assessments, independently conducted by the National Academies for Science, Engineering, and Medicine and the NASA Engineering & Safety Center, concluded that the technologies required for a high-power NEP system are immature and the attendant risks insufficiently quantified to justify initiating a flight project. For NEP to be available as a viable option to meet flight opportunities in the late 2030s / 2040s time frame, development of the key sub-systems must begin now. SNP has subdivided the NEP system into five Critical Technology Elements (CTE): the nuclear reactor, power conversion, power management and distribution, electric propulsion sub-system, and the primary heat rejection system. Development plans for each of these CTEs have been drafted which will serve as the template for a focused milestone-driven research and development campaign intended to advance each CTE to Technology Readiness Level (TRL) 5. This will be accomplished by building and testing hardware at relevant power levels (~ 1 MW) and for relevant durations (2,500 hours, ~10% of the required operational lifetime) and conducting numerical modeling of the CTEs anchored by the accumulated test data to predict system performance and reliability. Concurrent with this work, high-level coupled system/mission modeling will be carried out to refine the key performance parameters that the various CTEs must achieve. Non-advocate reviews will be held at milestone points to assess progress and inform down-select decisions. The strategy for formulating the TMP was described previously*; this paper describes ongoing progress on the drafting and baselining of the plan, including key specific details. * “Strategy for Developing Technologies for Megawatt-class Nuclear Electric Propulsion Systems”, K.A. Polzin, et. al., International Electric Propulsion Conference IEPC 2022, IEPC-2022-155

Nuclear Electric Propulsion↗

Silicon Carbide Sensors and Electronics Technology for Extreme Environments: Opportunities for Nuclear Power Applications

Over the past five decades, NASA Glenn Research Center had been advancing the development of single crystal silicon carbide growth, sensors and electronics device technologies, culminating in the recent demonstration of Micro-Electro-Mechanical Systems scale batch fabricated pressure sensors operating at 800 °C and integrated circuit electronics with demonstrated durability of over 1000 hours at 500 °C. As a result of the progress made in demonstrating the high temperature capability of the technology, insertion into actual operational environments, such as in jet engines and planet Venus, are in progress. The high temperature, near inert surface chemistry, and radiation hardness attributes of SiC, coupled with the relative maturation of the device batch microfabrication, contact metallization, and packaging technologies, make the material a prime candidate for use as part of future advanced nuclear reactor instrumentation and control strategy. Hence the current research efforts at NASA Glenn are aimed toward harnessing these attributes in developing SiC sensors and electronics for nuclear reactor applications, potentially for future Lunar/Martian nuclear power and the emerging terrestrial micro nuclear power plants.

silicon carbide↗

Nuclear Thermal Propulsion Material Trade for Additively Manufactured Regenerative Chambers

Nuclear thermal propulsion (NTP) is a game changing technology with advantages over chemical propulsion systems for deep space missions but comes with many engineering challenges. This paper focuses on the challenge of material selection for a regeneratively-cooled chamber for use in a nuclear environment with minimal design margins. Chemical compatibility with reactants and products following energy extraction (be it through combustion or neutron bombardment) must be considered. Similarly, mechanical and thermophysical properties (e.g., density, thermal conductivity, yield strength, etc.) as functions of temperature are critical. While hydrogen embrittlement environment (HEE) is a risk and consideration for traditional chemical combustion chambers, application in a nuclear thermal engine adds additional material compatibility and resilience requirements to long-term nuclear radiation exposure. Chamber materials in this trade included, but were not limited to, A-286, Haynes 230, Haynes 282, CRES 347, GRCop-42, GRCop-84, Inconel 625, JBK-75, and NASA HR-1. The material trade focuses on modern additive manufacturing techniques and hypothetical geometric constraints.

Nuclear Thermal Propulsion↗

Radiation and Nuclear Technology in Planetary Cave Environments

Many technological and environmental challenges must be resolved to enable successful lunar habitation and exploration, and to maximize scientific return. This presentation is intended as a preliminary discussion on three such areas of interest with the intent to identify likely areas of mutual benefit for collaboration and data sharing between the space nuclear and radiological disciplines with the planetary cave community. First is the previously identified and studied possible application of lunar lava tubes or pits to reduce the solar and cosmic radiation environment burden on crew health and hardware reliability. This is an area of continued interest, and should be kept in the forefront of discussion during the selection of sites for potential exploration or long-term habitation. In theory, the prospect of using existing morphology presents an enticing opportunity to reduce the requirements on landed mass or construction while also reducing dose or fluence of harmful natural radiation. However, such discussions should also include the practical implications of relocating habitation hardware and personnel from a landing site to a subsurface location. Inherent risks associated with landing in proximity to the relevant terrain must also be considered and weighed against those imposed by the natural radiation environment. Second is a discussion on the means by which a long-term habitation module or base of operations may be powered throughout the lunar day-night cycle. Fission surface power presents an opportunity to establish round-the-clock power in any lunar surface environment, including permanently shadowed regions where solar panels cannot operate, or in any other non-polar region where solar radiation is available for no more than two weeks per four-week cycle. Among the drawbacks of fission surface power is the need to either land and co-locate a heavy shield to minimize radiological consequences to personnel or equipment, land and operate construction equipment capable of restructuring the in-situ regolith to provide appropriate shielding, or to make use of existing topology features (e.g. craters or pits) to serve as pre-formed radiation barriers. A realistic assessment of the practicality of this third option should involve the selection of candidate features from existing surveys, and assess the effectiveness of the approach using modern radiation transport methodologies. Consideration must be made for the needs to reject waste heat in the thermal power conversion process, which typically requires the use of large area radiators. Energy must be exchanged from the reactor and power conversion system to such radiators, and the impacts on thermal efficiency and secondary scatter of nuclear radiation must be considered. Further consideration should be made for the implications of placement of a power source such that it does not sacrifice valuable scientific opportunity. Placement of a reactor is likely to thereafter prevent personnel access within that feature. Third is a discussion on the use of portable radioisotope power systems (RPS) within confined spaces, both with respect to the dose effects of emitted nuclear radiation and also performance associated with emitted thermal radiation. Radioisotope power systems provide a unique capability to power objects with no reliance upon solar radiance. However, their useable power production relies upon the flow of heat from ‘hot side’ (decaying radioisotope) to ‘cold side’ (radiators emitting heat to space). In the case of a confined volume in vacuum such as a lunar lava tube, that radiated energy will absorb into the wall, which is already above the ‘cold background’ temperature of dark space, and then gradually rises in temperature. That temperature rise, and its implications on availability of useable electrical power, will depend upon factors such as enclosure volume, thermal emissivity/absorptivity, and thermal conductivity through the depth of absorbing media. The advantages of nuclear technology may prove to enable unique scientific exploration opportunities, both above the lunar surface and below. In turn, the unique advantages of lunar lava tubes or pits may present unique opportunities to enhance the application of these technologies and to mitigate the effects of radiation from both natural and technological sources. A discussion on these pairings may prove to be valuable to all, in our endeavor to explore our neighboring worlds.

Radiation↗

Radiation Effects Considerations for Instrumentation and Control in Space Nuclear Systems

Radiation effects in electrical, electronic, electro-motive, and electro-optical (EEEE) hardware encompass a complex variety of interactions, processes, environments, and an evolving landscape of relevant hardware. Appropriately mitigating the effects of radiation in sensors, data acquisition, and control hardware is among the most significant challenges associated with deploying space nuclear power and propulsion systems. The expertise within EEEE radiation effects disciplines require working knowledge that is at least as complex and diverse as the problem itself, but that should not dissuade stakeholders and engineers in adjacent disciplines from attempting to understand the general principles associated with the problem at hand. This brief overview seeks to bring to the foreground a set of relevant topics that are of special importance for space nuclear propulsion applications that involve high rates of neutron and gamma radiation. The unique set of environments and design requirements for space nuclear systems mean that the experience and utility for methods applied to typical spaceflight hardware or terrestrial nuclear systems must not be applied naively. Forward consideration on the applicability of testing methods applied to either existing or bespoke hardware is likely to drive early decisions on system-wide radiation effects mitigation strategies, and will influence procurement requirements for providers of radiation tolerant hardware who are unlikely to have experience in this unique set of environments. Radiation hardness assurance (RHA) guidance should be adapted and emphasize the importance of hardware testing in the relevant environment. These must consider the combined effects of temperature, total ionizing dose (TID), non-ionizing/displacement damage (TNID/DD), and single event effects (SEE), and should consider the impacts of flux (rate) in addition to cumulative effects.

Radiation↗

Fabrication and Mechanical Testing of Heat Exchanger Tubes for Nuclear Propulsion and Other Applications from Continuous Carbon Nanotube Yarns and Tapes

As NASA and other agencies are looking to conduct sustained operations in space, nuclear engines have been receiving increased focus. The high specific impulse and high fuel efficiency at high thrust output of these engines can halve the transit time for human missions to Mars, or enable missions requiring multiple orbital parameter adjustments. In both Nuclear Thermal Propulsion (NTP) and Nuclear Electric Propulsion (NEP) systems, heat exchangers play a critical role in transferring energy from the reactor to a working fluid, hydrogen in the case of NTP and a molten salt or other fluid for electricity generation in NEP. Heat exchangers are also required in other parts of the spacecraft. Various manufacturing methods and materials are being considered for the heat exchangers. In this presentation the fabrication and testing of heat exchangers made from continuous carbon nanotube (CNT) yarns and tapes are discussed. The fabrication workflow is compared and contrasted, as well as performance of prototype heat exchanger tubes fabricated using the various CNT formats. The failure loads and mechanisms of the tubes under tensile, compression, and bending loads are assessed. A further comparison of the CNT materials to components fabricated from carbon fiber is made. The presented work will contribute to the selection of approaches for heat exchanger fabrication methods for nuclear propulsion and other applications.

Heat Exchanger↗

Airbreathing nuclear propulsion: A new look

Nuclear-powered air-cushion vehicles using lightweight aircraft-type nuclear powerplants show promise of carrying transoceanic cargo at cost-per-metric-ton-kilometer (cost-per-ton-n mi) rates comparable to railroad rates. These rates are independent of the distance traveled. Cargo rates for nonstop distances of 4000 n mi are expected to be less than one-half those for similar fossil-fueled air-cushion vehicles. For 6000-n mi nonstop distances, the rates are expected to be less than one-sixth as much. There are no fundamental technical reasons why subsonic nuclear aircraft cannot be made to fly successfully if the gross weight is over 1 million lb. Public safety of airborne nuclear powerplants is receiving the greatest attention in low-level experimental and analytical investigations. Idealized model containment vessels which have been impacted on reinforced concrete showed no leaks after impact at velocities to 400 mph. The experiments indicate feasibility of impacting at speeds over 600 mph with no leaks.

Rom, F. E.↗

Space Nuclear Propulsion Systems and Applications

The basic principles of the operation of a nuclear rocket engine are reviewed along with a summary of the early history. In addition, the technology status in the nuclear rocket program for development of the flight-rated NERVA engine is described, and applications for this 75,000-pound thrust engine and the results of nuclear stage studies are presented. Advanced research and supporting technology activities in the nuclear rocket program are also summarized.

Schwenk, F. C.↗

Space nuclear power systems

Space nuclear power systems are considered for use in those particular spacecraft applications for which nuclear power systems offer unique advantages over solar and/or chemical space power systems. Both isotopic and reactor heated space electrical power units are described in an attempt to illustrate their operating characteristics, spacecraft integration aspects, and factory-to-end of mission operational considerations. The status of technology developments in nuclear power systems is presented. Some projections of those technologies are made to form a basis for the applications of space nuclear power systems to be expected over the next 10-15 years.

Carpenter, R. T.↗

Nuclear radiation problems, unmanned thermionic reactor ion propulsion spacecraft

A nuclear thermionic reactor as the electric power source for an electric propulsion spacecraft introduces a nuclear radiation environment that affects the spacecraft configuration, the use and location of electrical insulators and the science experiments. The spacecraft is conceptually configured to minimize the nuclear shield weight by: (1) a large length to diameter spacecraft; (2) eliminating piping penetrations through the shield; and (3) using the mercury propellant as gamma shield. Since the alumina material is damaged by the high nuclear radiation environment in the reactor it is desirable to locate the alumina insulator outside the reflector or develop a more radiation resistant insulator.

Mondt, J. F.↗

Flowing gas, non-nuclear experiments on the gas core reactor

Flow tests were conducted on models of the gas core (cavity) reactor. Variations in cavity wall and injection configurations were aimed at establishing flow patterns that give a maximum of the nuclear criticality eigenvalue. Correlation with the nuclear effect was made using multigroup diffusion theory normalized by previous benchmark critical experiments. Air was used to simulate the hydrogen propellant in the flow tests, and smoked air, argon, or freon to simulate the central nuclear fuel gas. All tests were run in the down-firing direction so that gravitational effects simulated the acceleration effect of a rocket. Results show that acceptable flow patterns with high volume fraction for the simulated nuclear fuel gas and high flow rate ratios of propellant to fuel can be obtained. Using a point injector for the fuel, good flow patterns are obtained by directing the outer gas at high velocity along the cavity wall, using louvered or oblique-angle-honeycomb injection schemes.

Kunze, J. F.↗

Nuclear pumping of lasers.

Summary of the theoretical and experimental work dealing with nuclear lasers that has been completed during the last year (1971), and review of some new work which may help to establish the direction research in this field may take in the future. So far, the most successful experiments have been carried out utilizing nuclear enhancement of electrically excited CO2 lasers. The goal of attaining lasing in gases utilizing nuclear pumping without an applied electric field is much more difficult to achieve but is being pursued. No experimental or theoretical work has been undertaken thus far in the study of the class of lasers where high-energy particles are produced internally in high-temperature multiple ionized plasmas. Some new approaches to high-power nuclear lasers are suggested.

Russell, G. R.↗

Nuclear processes associated with peculiar A-type stars.

A discussion is given of the various roles that nuclear reactions may play in production of anomalous abundances of elements in peculiar A stars. The effects which may be expected to occur both in the surface nuclear reactions and in some possible internal reactions that can occur in advanced stages of stellar evolution are considered. It is suggested that various features of peculiar A stars may require simultaneous operation of two or more of the processes of surface diffusion, surface nuclear reactions, and internal nuclear reactions.

Cameron, A. G. W.↗

Conceptual design studies and experiments related to cavity exhaust systems for nuclear light bulb configurations

Investigations of various phases of gaseous nuclear rocket technology have been conducted. The principal research efforts have recently been directed toward the closed-cycle, vortex-stabilized nuclear light bulb engine and toward a small-scale fissioning uranium plasma experiment that could be conducted in the Los Alamos Scientific Laboratory's Nuclear Furnace. The engine concept is based on the transfer of energy by thermal radiation from gaseous fissioning uranium, through a transparent wall, to hydrogen propellant. The reference engine configuration is comprised of seven unit cavities, each having its own fuel transparent wall and propellant duct. The basic design of the engine is described. Subsequent studies performed to supplement and investigate the basic design are reported. Summaries of other nuclear light bulb research programs are included.

Kendall, J. S.↗