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DOE OSTI2025

Ultra-high temperature testing and performance of L-PBF C103

Additive Manufacturing (AM) of refractory alloys is gaining traction as a materials processing route for components subject to extreme temperature environments. Due to the low oxidation resistance of refractory alloys, novel methods for evaluating their elevated temperature performance must be developed. In this work, a Gleeble® 3800 thermomechanical load frame was modified to evaluate the mechanical properties of laser powder bed fusion (L-PBF) consolidated niobium alloy C103 ranging from room temperature (RT) to 1400 °C. The fixturing and sample geometry were designed to accommodate Joule heating and prevent damage to the test chamber. Oxidation of the samples was minimized via testing in vacuum level of 1E-5 Torr. Ultimate tensile strength (UTS), yield strength (YS), elongation, and strain-hardening behavior were determined as a function of temperature. L-PBF C103 presented an average UTS of ∼650 MPa and over 25 % elongation at RT. Above RT, the UTS and YS dropped then leveled off from 500 °C to 1000 °C with values ranging from ∼400 MPa to ∼460 MPa, which is consistent with dynamic strain aging observed in this class of alloys. The strength rapidly declined after 1200 °C to ∼150 MPa at 1400 °C. Fractography indicated ductile fractures for the C103 at all test temperatures, and Electron Backscatter Diffraction (EBSD) analysis revealed a textured microstructure and the presence of dynamic recrystallization within the necked region of the sample tested at 1400 °C.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Novel adaptive immune systems in pristine Antarctic soils

Antarctic environments are dominated by microorganisms, which are vulnerable to viral infection. Although several studies have investigated the phylogenetic repertoire of bacteria and viruses in these poly-extreme environments with freezing temperatures, high ultra violet irradiation levels, low moisture availability and hyper-oligotrophy, the evolutionary mechanisms governing microbial immunity remain poorly understood. Using genome-resolved metagenomics, we test the hypothesis that Antarctic poly-extreme high-latitude microbiomes harbour diverse adaptive immune systems. Our analysis reveals the prevalence of prophages in bacterial genomes (Bacteroidota and Verrucomicrobiota), suggesting the significance of lysogenic infection strategies in Antarctic soils. Furthermore, we demonstrate the presence of diverse CRISPR-Cas arrays, including Class 1 arrays (Types I-B, I-C, and I-E), alongside systems exhibiting novel gene architecture among their effector cas genes. Notably, a Class 2 system featuring type V variants lacks CRISPR arrays, encodes Cas1 and Cas2 adaptation module genes. Phylogenetic analysis of Cas12 effector proteins hints at divergent evolutionary histories compared to classified type V effectors and indicates that TnpB is likely the ancestor of Cas12 nucleases. Our findings suggest substantial novelty in Antarctic cas sequences, likely driven by strong selective pressures. These results underscore the role of viral infection as a key evolutionary driver shaping polar microbiomes.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1981

Additional extensions to the NASCAP computer code, volume 1

Extensions and revisions to a computer code that comprehensively analyzes problems of spacecraft charging (NASCAP) are documented. Using a fully three dimensional approach, it can accurately predict spacecraft potentials under a variety of conditions. Among the extensions are a multiple electron/ion gun test tank capability, and the ability to model anisotropic and time dependent space environments. Also documented are a greatly extended MATCHG program and the preliminary version of NASCAP/LEO. The interactive MATCHG code was developed into an extremely powerful tool for the study of material-environment interactions. The NASCAP/LEO, a three dimensional code to study current collection under conditions of high voltages and short Debye lengths, was distributed for preliminary testing.

Mandell, M. J.↗

DOE OSTI2023

Predicting oxidation damage of ultra high-temperature carbide ceramics in extreme environments using machine learning

Determining the oxidation resistance of UHTC carbides in extreme environments is challenging theoretically and experimentally due to the high dimensional complexity of influencing variables and intricate testing setups. Herein we demonstrate the use of machine learning (ML) models trained with experimental literature data to predict the oxide thickness of UHTC carbides exposed to air based on composition, mean grain size, relative densification, holding time, and temperature. A multi-dimensional database with 76 occurrences is created containing experimental results of Hf, Zr, and Ta carbides plus additives. In this study, the preprocessed database is then used to train ML models to predict their oxidation behavior. The trained model predicts the oxidation damage in the form of an average oxide thickness in UHTC carbides with a Mean Absolute Error (MAE) of ±65.45 μm for samples in the testing set that developed thicknesses up to 1000 μm. The model successfully predicted oxidation damage for a recession rate lower than 60 μm/min. It is noticed that the ensemble method MAE is increased to ±134.34 μm while forecasting the oxidation of samples with a recession rate higher than the threshold. The unprecedented approach is a novel way to predict the damage through the oxidation of carbide compounds before processing for a smarter design with room for improvement.

36 MATERIALS SCIENCE↗

NASA NTRS1992

Environmental qualification testing of payload G-534, the Pool Boiling Experiment

Payload G-534, the prototype Pool Boiling Experiment (PBE), is scheduled to fly on the STS-47 mission in September 1992. This paper describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave wider latitude in determining which shuttle thermal attitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the hardware build laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.

Sexton, J. Andrew↗

NASA NTRS1992

Environmental qualification testing of the prototype pool boiling experiment

The prototype Pool Boiling Experiment (PBE) flew on the STS-47 mission in September 1992. This report describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the prototype hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave the project team a wider latitude in determining which shuttle thermal altitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the project's laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.

Sexton, J. Andrew↗

NASA NTRS2020

TPS and Entry Technologies for Future Outer Planet Exploration

The lack of knowledge about the Ice Giants (Voyager being the only probe to briefly visit them) and literally narrow window of planetary alignment for pragmatic missions to the Ice Giants, make them high priority targets in the next decade. The purpose of this white paper is to provide an overview to the NRC Decadal Survey on thermal protection system (TPS) technologies required for future Outer Planet exploration missions. A prime conclusion is that several of the most significant recommendations made during the last decadal survey were addressed positioning the TPS community to better support missions to the Outer Planets. These include maturation of the Heatshield for Extreme Entry Environment Technology (HEEET) to TRL 6 as replacement for Carbon Phenolic (that requires requalification itself), TPS test facility upgrades, and design tool improvements. These new materials and test methods are enabling for Outer Planet missions. However, there are limitations in the HEEET technology and available ground based test facilities that could become mission constraints depending on the science objectives. This white paper discusses opportunities to mitigate those constraints. In addition, if a mission is not scheduled in the near future, these new developments are at risk of becoming unavailable. Therefore, we recommend that NASA invest in a cross-cutting technology program that focuses on sustainment of relevant TPS materials, entry systems, test facilities, design tools, and flight instrumentation.

Outer Planets↗

NASA NTRS2015

Mars OASIS (Mars Operational Agricultural System for In-Situ Specialization) System Reference Manual

In order to enable long term habitation on planetary surfaces, a means of sustainable food production must be developed. Addressing this need for surface habitats on Mars, the MarsOASIS team has developed a concept for a Martian surface greenhouse for unmanned crop production research as a proof of concept for larger scale food production facilities for manned surface missions. Utilizing in-situ resources such as the Martian atmosphere, sunlight, and UV-C radiation, the greenhouse aims to provide a sustainable method of long-term food production requiring minimal consumable resources. The MarsOASIS system is capable of growing a full life cycle of Outredgeous lettuce with its autonomous control system designed for a unmanned environment, only requiring teleoperation in extreme circumstances. A reduced-scope prototype of MarsOASIS is being developed to test technologies such as a natural/artificial hybrid lighting system, a closed water recycling system, remote teleoperation, and fully autonomous monitoring and control of the greenhouse. The prototype is currently in the final stages of design, with a full demonstration of plant life cycle testing set to occur in summer 2015. Results from this prototype demonstration will help quantify the feasibility of the innovative approaches seen in the MarsOASIS design.

Asa Darnell↗

NASA NTRSDate not supplied

Heat Transfer Measurements of NASA Liquid Kerosene/Oxygen Rotating Detonation Rocket Engine

The RDRE has been identified as a viable high performance propulsion system with numerous advantages over the state-of-the-art (SOA) liquid rocket engine. NASA has been investigating this combustion device for applications ranging from lander, upper stage, thruster, and hypersonics. All of the activities funded to date have been focused on closing major technology gaps preventing the RDRE from being used more broadly by industry. One of those gaps include the prediction and management of heat transfer to the walls from the extreme combustion environment. This work overviews the heat transfer measurements made using new and existing hardware. A liquid oxygen / liquid RP-1 RDRE was tested utilizing a calorimeter outer body and outer body nozzle extension. An actively cooled inner body with axial running cooling channels was also used. A bimetallic GRCop-42 / Monel K500 injector was developed and demonstrated to be a viable technology for RDRE environments. Trends in bulk heat loads are discussed along with a direct comparison to constant pressure theory predictions of wall heat transfer. The experimental data obtained in this investigation showed similar heat fluxes to constant pressure theory indicating deflagration may have dominated the flow field. Only a single detonation wave was observed in all tests which imparted a significant dynamic load (vibration) on the test article making measurement of combustor performances extremely challenging. Both accelerometer and load cell data corroborate the extreme G-forces measured. The single wave mode yielded relatively low performances compared with other hot fire test data sets available. This leads to the conclusion that a single detonation wave in this geometry is not sufficient for high performance. Wave multiplicity, or rather, a specific number of waves may yield higher performances.

Thomas Teasley↗

NASA NTRS1986

Evaluation of 2 cognitive abilities tests in a dual-task environment

Most real world operators are required to perform multiple tasks simultaneously. In some cases, such as flying a high performance aircraft or trouble shooting a failing nuclear power plant, the operator's ability to time share or process in parallel" can be driven to extremes. This has created interest in selection tests of cognitive abilities. Two tests that have been suggested are the Dichotic Listening Task and the Cognitive Failures Questionnaire. Correlations between these test results and time sharing performance were obtained and the validity of these tests were examined. The primary task was a tracking task with dynamically varying bandwidth. This was performed either alone or concurrently with either another tracking task or a spatial transformation task. The results were: (1) An unexpected negative correlation was detected between the two tests; (2) The lack of correlation between either test and task performance made the predictive utility of the tests scores appear questionable; (3) Pilots made more errors on the Dichotic Listening Task than college students.

Vidulich, M. A.↗

NASA NTRSDate not supplied

Use of Tardigrade Proteins for Enhancing Cellular Stress Tolerance on the Moon

With sights set on returning a human presence to the Moon and plans to explore even farther beyond, it is imperative we understand the impact of deep space radiation, partial gravity, and the lunar surface on biology. The need for countermeasures to protect future astronauts from the unique conditions of space is ever-pressing and an assessment of bioproduction capabilities in space is a crucial step for sustaining long-term missions. The Lunar Explorer Instrument for space biology Applications (LEIA) aims to investigate the cell’s response to the lunar environment and test strategies for enhancing cellular tolerance on the Moon, utilizing the budding yeast Saccharomyces cerevisiae as a biosensor. S. cerevisiae serves as an excellent model organism due to its widespread use as an analog for human cells, well-characterized set of genetic tools, and ability to survive desiccation. However, these cells must remain desiccated for up to one year prior to launch and the radiation-sensitive strains designed for LEIA will likely be more vulnerable to desiccation effects. In this work, we introduce tardigrade proteins known for their protective mechanisms into potential LEIA strains to test genetic strategies for improving desiccation and radiation tolerance. Tardigrades are extremotolerant animals well-known for their ability to survive in harsh environments. Notably, they can survive extreme desiccation and radiation due to the upregulation of intrinsically disordered proteins (IDPs). It has been shown that integration of these tardigrade IDPs, such as cytosolic abundant heat-soluble (CAHS) proteins, into yeast can confer increased desiccation tolerance in synergy with trehalose. Our ongoing testing and assessment of bioengineered radiation and desiccation tolerance will help us gain insight into optimizing strain design and selection for protecting LEIA’s biological payload as well as genetic engineering strategies for enhancing bioproduction potential for future missions beyond low Earth orbit.

Genetics↗

NASA NTRSDate not supplied

Use of Tardigrade Proteins for Enhancing Cellular Stress Tolerance on the Moon

Genetics↗

DOE OSTI2021

Characterization of advanced nuclear materials under extreme environments

The performance of materials under extreme environments poses important fundamental questions about the behavior of condensed matter under far-from-equilibrium conditions. These conditions create challenges in materials design, testing and evaluation. One important aspect of advancing nuclear power is the discovery and investigation of new classes of materials able to withstand the harsh environments in nuclear reactors. However, investigating and understanding the performance of these materials requires sophisticated tools and characterization techniques and skills. Furthermore, the goal of this special issue is to present recent research on the characterization of the response of candidate advanced nuclear materials to extreme environments.

36 MATERIALS SCIENCE↗

NASA NTRS1999

Oxidation Resitant HfC-TaC Rocket Thruster for High Performance Propellants

The purpose of this reasearch effort was to develop high temperature, oxidation resistant thrusters which would lessen the thruster cooling requirements, resulting in increased performance and longer life for onboard propulsion systems for spacecraft. This research effort focussed on developing ceramic matrix composites (CMCs) for this application, and specifically investigated the use of HfC stabilized with TaC. This material composition can potentially operate in a stoichiometric oxygen to hydrogen ratio at a temperature of 5000 deg F (2760 deg C) in a radiatively cooled mode. Various compositions of Hafnium Carbide (HfC) and Tantalum Carbide (TaC) were deposited by chemical vapor deposition (CVD) and tested, in an attempt to identify the composition which offered the best oxidation resistance. Although it was identified that small amounts of TaC appeared to offer improved oxidation resistance over HfC alone, an optimal composition was not identified. A 251bf thruster was fabricated from a novel CMC sandwich construction with a HfC-TaC matrix, and survived two test firings, each of 5 seconds before a failure in the injector caused the run to be aborted. It was not possible to control the relative stoichiometry of the HfC and TaC composition throughout the reactor due to the large difference in the thermodynamics of the HfC and TaC formation from their respective chlorides. This also resulted in an inability to infiltrate TaC into the preform under the experimental conditions investigated. Other material compositions were fabricated and tested and two material systems; HfC-SiC functionally graded to C(sub f)/C and Re functionally graded to C(sub f)/C were selected for further testing. These functionally graded composites have use in a number of propulsion applications presently of interest to NASA and the defense industry. Their ability to withstand extremely hostile thermal environments and the light-weight and high-strength exhibited from the C(sub f)/C composite make these materials particularly suited for these applications. In the Phase III which is presently underway, Re functionally graded to C(sub f)/C is being further developed and tested for application in the thrust cells for the Linear Aerospike Engine for the X33 and RLV.

Patterson, Mark↗

NASA NTRS2001

Field Science Ethnography: Methods For Systematic Observation on an Expedition

The Haughton-Mars expedition is a multidisciplinary project, exploring an impact crater in an extreme environment to determine how people might live and work on Mars. The expedition seeks to understand and field test Mars facilities, crew roles, operations, and computer tools. I combine an ethnographic approach to establish a baseline understanding of how scientists prefer to live and work when relatively unemcumbered, with a participatory design approach of experimenting with procedures and tools in the context of use. This paper focuses on field methods for systematically recording and analyzing the expedition's activities. Systematic photography and time-lapse video are combined with concept mapping to organize and present information. This hybrid approach is generally applicable to the study of modern field expeditions having a dozen or more multidisciplinary participants, spread over a large terrain during multiple field seasons.

Clancey, William J.↗

NASA NTRS2007

Solid Lubricants and Coatings for Extreme Environments: State-of-the-Art Survey

An investigation was conducted to survey anticipated requirements for solid lubricants in lunar and Martian environments, as well as the effects of these environments on lubricants and their performance and durability. The success of habitats and vehicles on the Moon and Mars, and ultimately, of the human exploration of and permanent human presence on the Moon and Mars, are critically dependent on the correct and reliable operation of many moving mechanical assemblies and tribological components. The coefficient of friction and lifetime of any lubricant generally vary with the environment, and lubricants have very different characteristics under different conditions. It is essential, therefore, to select the right lubrication technique and lubricant for each mechanical and tribological application. Several environmental factors are hazardous to performance integrity on the Moon and Mars. Potential threats common to both the Moon and Mars are low ambient temperatures, wide daily temperature swings (thermal cycling), solar flux, cosmic radiation, and large quantities of dust. The surface of Mars has the additional challenges of dust storms, winds, and a carbon dioxide atmosphere. Solid lubricants and coatings are needed for lunar and Martian applications, where liquid lubricants are ineffective and undesirable, and these lubricants must perform well in the extreme environments of the Moon, Mars, and space, as well as on Earth, where they will be assembled and tested. No solid lubricants and coatings and their systems currently exist or have been validated that meet these requirements, so new solid lubricants must be designed and validated for these applications.

Miyoshi, Kazuhisa↗

NASA NTRSDate not supplied

Validation of Multisystem Countermeasures Protocol for Spaceflight during Antarctica Winter-over at Palmer Station (Palmer Countermeasures)

Stressors associated with spaceflight induce persistent immune compromise in astronauts which increase subclinical latent virus reactivation. In select crews, adverse clinical events have been documented. Antarctica winter-over (AWO) mission most closely reproduces these mission stressors: prolonged deployment, extreme environment, circadian misalignment, isolation, station lifestyle, and personal risk. The US maintains three primary stations in Antarctica: South Pole Station, McMurdo, and Palmer. Previous studies suggest that stations located near the interior of Antarctica (South Pole, McMurdo) have confounding effects on the immune system due to persistent hypobaric hypoxia. We hypothesized that winter-over at a coastal station (Palmer) would be more akin to spaceflight due to its normoxic but still extreme environment. Therefore, AWO at Palmer Station was selected, and validated in a pilot study, as the platform for testing and validating the effectiveness of an immune-restorative countermeasure protocol designed for deep space missions. Specifics include diet modifications, nutritional supplementation (vitamin D, probiotic, etc.), prescribed aerobic and resistive exercise, and a protocol of stress relieving virtual reality exercises. A multitude of biological sample types, including blood, saliva, and hair will be collected in tandem with the countermeasures in order to examine the combined effectiveness of the countermeasures. Samples and logs from subjects will be transported from Palmer Station to Johnson Space Center for further processing and distribution to co-investigators at the end of each winter-over. Extracted samples will be analyzed by appropriate testing platforms (Multiplex, qPCR, ELISA, etc.) to monitor alterations in leukocyte distribution, T cell and NK function, cytokine profiles, reactivation of latent herpesviruses, and nutritional factors. The data collected will be compared to a control year in which no countermeasures were deployed to evaluate the overall effectiveness of the analog and to validate the candidate immune countermeasure strategy. AWO 2023 concluded with the 4th in-mission timepoint conducted in September 2023. Samples for 16 subjects, including blood, saliva, hair, surveys, and PCR data, were all successfully returned from Antarctica to NASA/JSC mid-November 2023. Samples have since been distributed to co-investigators for further processing and analysis. With the completion of the first countermeasure year, preliminary data on the effectiveness of the deep-space protocol is being evaluated, however, no conclusions can be drawn yet until the completion of the second AWO countermeasure year, AWO 2024. AWO 2024 commenced in late-March 2024, with 13 subjects consenting and performing their baseline data collections (BDCs). Unique to the 2024 deployment, NSF lifted certain COVID restrictions and rallied the crewmembers in Punta Arenas, Chile. All NSF activities were transferred to this location and NASA was allowed, for the first time, to perform consent briefings, baseline samplings and training in person. This augment greatly increased the likelihood of success for the overwinter activities.

Cody L Gutierrez↗

NASA NTRS2013

The Challenges of Integrating Instrumentation with Inflatable Aerodynamic Decelerators

To realize the National Aeronautics and Space Administration s (NASA) goal of landing humans on Mars, development of technologies to facilitate the landing of heavy payloads are being explored. Current entry, decent, and landing technologies are not practical when utilizing these heavy payloads due to mass and volume constraints dictated by limitations imposed by current launch vehicle fairings. Therefore, past and present technologies are now being considered to provide a mass and volume efficient solution, including Inflatable Aerodynamic Decelerators (IADs) [1]. IAD ground and flight tests are currently being conducted to develop and characterize their performance under flight-like conditions. The integrated instrumentation systems, which are key to the performance characterization in each of these tests, have proven to be a challenge compared to the instrumentation of traditional rigid aeroshells. To overcome these challenges, flexible and embedded sensing systems have been developed, along with improved instrumenting techniques. This development opportunity faces many difficult aspects specific to inflatable structures in extreme environments. These include but are not limited to: physical flexibility, packaging, temperature, structural integration and data acquisition [2]. To better define the instrumentation challenges posed by IAD technology development, a survey was conducted to identify valuable measurements for ground and flight testing. From this survey many sensing technologies were explored, resulting in a down-selection to the most viable prospects. These systems were then iterated upon in design to determine the best integration techniques specific to a 3m and 6m stacked torus IAD. Each sensing system was then integrated and employed to support the IAD testing in the National Full-Scale Aerodynamics Complex 40 x 80 wind tunnel at NASA Ames Research Center in the summer of 2012. Another challenge that has been explored is the data acquisition of IAD sensing technologies. Traditionally all space based sensing systems transmit their data through a wired interface. This limits the amount of sensors able to be integrated within the IAD due to volume and routing restrictions of the supporting signal and excitation wires. To alleviate this situation, multiple wireless data acquisition technologies have been researched and developed through rapid prototyping efforts. The final custom multi-nodal wireless system utilized during the summer 2012 IAD test series consisted of four remote nodes and one receiving base station. The system reliably conditioned and acquired 20+ sensors over the course of the wind tunnel test series. These developments in wireless data acquisition techniques can eliminate the need for structural feedthroughs and reduce system mass associated with wiring and wire harnesses. This makes the utilization of flight instrumentation more attractive to future missions, which would result in further improved characterization of IAD technology, and overall, increased scientific knowledge regarding the response of inflatable structures to extreme entry environments. [

Swanson, Gregory T.↗