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This presentation provides a high-level summary of recent fuel cell and electrolysis development activities at NASA for both aeronautic and aerospace applications. It highlights advances in PEM and solid oxide technologies implemented as primary fuel cells. It also includes the results of recent Lunar energy storage trade studies evaluating the feasibility of regenerative fuel cell energy storage.
Increasing temperatures in aero gas turbines is resulting in oxidation and hot corrosion attack of turbine disks. Since disks are sensitive to low cycle fatigue (LCF), any environmental attack, and especially hot corrosion pitting, can seriously degrade the life of the disk. Application of metallic coatings is one means of protecting disk alloys from this environmental attack. However, the presence of a metallic coating can degrade the LCF life of a disk alloy. Therefore, coatings must be designed which are not only resistant to oxidation and corrosion attack, but do not significantly degrade the LCF life of the alloy.Three different NiCr-Y coating compositions (29, 35.5, 44 wt.% Cr, all with 0.1 wt.% Y) were applied at two thicknesses by Plasma Enhanced Magnetron Sputtering (PEMS) to two similar Ni-based disk alloys. One Ni-35.5Cr-0.1Y coating also received a thin ZrO2 overcoat. The coated samples were also given a short thermal anneal in a low PO2 environment to encourage bonding of the coating and substrate as well as initiating formation of a chromia scale. Without further environmental exposure, the LCF life of coated and uncoated samples was evaluated at 760°C in air. The LCF lifetime of all coated samples was less than that of uncoated samples. The LCF life scaled with the Cr content and the high-Cr, thin coating showed the highest LCF life. Pre and post-test characterization of the various coatings, including identification of crack initiation sites, will be presented and the effect of the coating on the LCF life discussed.
In a prior companion study (Ref. 1), three different Ni-Cr coating compositions (29, 35.5, 45 wt% Cr) were applied at two thicknesses by Plasma Enhanced Magnetron Sputtering (PEMS) to two similar Ni-based disk alloys. One coating also received a thin ZrO2 overcoat. The low cycle fatigue (LCF) life of each coating was determined at 760 °C and was less than that of the uncoated specimens. In this followon effort, shot peening was examined as a means to improve the as-deposited coating morphology as well as impart a residual compressive stress in the near-surface region. After evaluating the effect of the shot peening on the LCF life, the effectiveness of the shot-peened coating in protecting the disk alloy from oxidation and hot corrosion attack was evaluated. This evaluation was accomplished by exposing coated and shot-peened specimens to 500 h of oxidation followed by 50 h of hot corrosion, both at 760 °C in air. These exposed specimens were then tested in fatigue and compared to similarly treated and exposed uncoated specimens. For all cases, shot peening improved the LCF life of the coated specimens. More specifically, the highest Cr coating showed the best LCF life of the coated specimens after shot peening, as well as after the environmental exposures. Characterization of the coatings after shot peening, oxidation, hot corrosion and LCF testing is presented and discussed.
It is an objective of the National Aeronautics and Space Administration (NASA) to return to the moon and to create sustained lunar operations. Since many applicable lander and upper stage vehicles utilize cryogenic hydrogen and oxygen propellants, it is appealing to incorporate fuel cells into potential mission concepts. A fuel cell could generate electricity, heat, and water from the residual hydrogen and oxygen propellants. Such a concept depends on the capability of the fuel cell to utilize dry, propellant-grade reactants at reduced pressures compared to typical fuel cell operating conditions. This report describes a NASA evaluation of two passive water removal, non-flow-through proton exchange membrane (PEM) fuel cells: a twelve-cell 50 sq. cm active area stack and a seven-cell 150 sq. cm active area stack. Both stacks operated on research grade hydrogen and oxygen reactants supplied at pressures ranging from 20 psia up to the 45-48 psia design operating point, reliably supporting current densities of at least 450 mA/sq. cm at reduced pressures. Polarization curves, fitted with a semi-empirical equation for overpotential, show an increase in effective ohmic resistance and decrease in reversible cell potential, hydrogen crossover current, and Tafel slope when operating at lower pressures, resulting in a reduction in cell voltage at all current densities. Fitted parameters are compared to published values and rationalized with first principles explanations.
What You Will Learn: The focus is on payload imaging performance due to pointing motion. Some historical background on pointing performance analysis is given. The Optical Transfer Function (OTF) and Modulation Transfer Function (MTF) are defined. The imaging performance due to pointing motion is measured by image motion optical transfer functions (IM OTF). IM OTFs are defined for displacement, smear, and jitter motions, which are all rigorously defined. Deterministic and Statistical IM OTFs are briefly derived and graphically illustrated and compared. The IM OTFs are parameterized by pointing error metrics(PEM), which are means and covariances of displacement, smear, and jitter. Emphasis is on procedures and algorithms to evaluate the image motion optical transfer functions and pointing error metrics. Three procedures are covered, which depend on whether the pointing error data is from time-domain simulation, frequency-domain analysis, or stochastic modeling. A method to evaluate the relative contribution of disturbance sources and to identify the most significant contributors is presented. The presentation includes pertinent discussion of flexible structures and control-structure interaction. No single book can adequately cover this subject, so a book is not required for the course. A list of selected articles, reports, documents, and books is provided for reference and further study. Mathis kept to the minimum necessary to convey principles; lengthy derivations are left to the reference material. Graphics are used to illustrate concepts. As with any such learning endeavor, the knowledge gained will be retained and strengthened through actual practice.c©2019–2021 Mark E. Pittelkau— 5
It is expected that future NASA mission energy storage needs can be adequately met by regenerative fuel cells (RFCs). Aerospace RFCs package proton exchange membrane (PEM) electrochemical conversion devices based on hydrogen, oxygen, and water. To optimize system designs and direct further development, the most useful system metric is round-trip efficiency (RTE). Improving RTE generally increases specific energy and reduces system mass. The following analysis models the impact of several factors on RTE for RFCs at the lunar south pole scaling from 0.1 kW to 50 kW. The analysis demonstrates that higher electrolyzer operational pressure most negatively impacts both RFC RTE and specific energy. Optimal electrolyzer membrane thickness is evaluated as a function of operational current density and pressure. Reactant storage heating and power management losses are significant for RFCs of any scale but are reduced in impact at the south pole compared to colder equator applications. Solenoid valve power remains a noticeable parasitic load for smaller RFCs. Larger electrolyzers enable higher peak theoretical efficiencies when recharging at higher rates, if the RFC can be coupled with a corresponding higher power source. RFC design is a compromise of many interrelated factors, but this analysis provides a starting point for difficult decisions that must be made when designing a lunar south pole RFC.
NASA’s Multi-Angle Imager for Aerosols (MAIA) mission, under development at the Jet Propulsion Laboratory, is designed to study the adverse health effects of different types of particulate air pollution. Planned for launch in 2023 for a 3-year mission, the MAIA satellite instrument will focus on a selected set of metropolitan target areas, where air quality monitors and health data are available. Aerosol concentration and speciation are inferred from multi-angle measurements of backscattered sunlight in 14 spectral bands from 350-2200 nm, with bands near 442, 645 and 1040 nm measuring the degree (DoLP) and angle of linear polarization (AoLP) in addition to radiance. The pushbroom camera has a ~240-km cross-track field of view with a nadir resolution of ~200 m, and is mounted onto a biaxial gimbal to provide along-track view angles within ±60°, to extend the field of regard to ±48°, and to view the instrument’s onboard calibrator (OBC) and dark target. The OBC consists of a sunlit transmissive diffuser, followed by 12 polarizers at different orientations. MAIA’s polarimetry is implemented using miniature wire grid polarizers on the focal plane array, and dual photoelastic modulators (PEMs) and achromatic quarter-wave plates to rapidly rotate the polarization. The resulting ~26-Hz intensity modulation encodes the linearly polarized and total radiance in each pixel, leaving the DoLP and AoLP insensitive to gain calibration. We report on the polarimetric calibration of the MAIA camera using a vacuum-compatible polarization state generator, consisting of a 1600W Xenon lamp, 12-inch integrating sphere, and rotating high-extinction polarizer. Mueller-matrix-based calibration coefficients for each detector pixel are derived from measurements at multiple polarizer angles, and are used to correct the measurements for instrumental polarization aberrations. Prior to flight, the calibrated MAIA camera is panned across the OBC to characterize its output, using uniform illumination with an irradiance similar to the Sun.
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Water vapor distributions, as measured by the Lidar Atmospheric Sensing Experiment (LASE), are shown to be a reliable indicator of stratospheric-tropospheric exchange events.
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This paper summarizes some of the recent progress in the development of cells, stacks, and systems.
Direct methanol fuel (DMFCs) have high potential for use in transportation applications because the fuel, unlike hydrogen, is relatively simple to generate, transport and store.
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Regenerative fuel cells provide a pathway to energy storage system development that are game changers for NASA missions. The fuel cell/ electrolysis MEA performance requirements 0.92 V/ 1.44 V at 200 mA/cm2 can be met. Fuel Cell MEAs have been incorporated into advanced NFT stacks. Electrolyzer stack development in progress. Fuel Cell MEA performance is a strong function of membrane selection, membrane selection will be driven by durability requirements. Electrolyzer MEA performance is catalysts driven, catalyst selection will be driven by durability requirements. Round Trip Efficiency, based on a cell performance, is approximately 65%.
A conceptual design was performed for a 6-U cubesat for a technology demonstration to be launched on the NASA Space Launch System (SLS) test launch EM-1, to be launched into a free-return translunar trajectory. The mission purpose was to demonstrate use of electric propulsion systems on a small satellite platform. The candidate objective chosen was a mission to visit a Near-Earth asteroid. Both asteroid fly-by and asteroid rendezvous missions were analyzed. Propulsion systems analyzed included cold-gas thruster systems, Hall and ion thrusters, incorporating either Xenon or Iodine propellant, and an electrospray thruster. The mission takes advantage of the ability of the SLS launch to place it into an initial trajectory of C3=0.
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