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NASA NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗

NASA NTRS1999

ISINT Performance Validation Test Report

The Satellite Networks and Architectures branch is researching the application of standard Internet technologies over satellite communication links to LEO spacecraft. The In-Space Internet Testbed (ISINT) simulates this communications path through the use of two experimental subnets of workstations communicating over the Advanced Communications Technology Satellite (ACTS) proof-of-concept radio frequency testbed. In order to validate the end-to-end performance of ISINT, similar file transfers were sent over the RF testbed and over an actual ACTS T1 link. Comparison of the results shows that the ISINT facility has very similar performance to communications over ACTS. This test was only for a stationary point-to-point, bent pipe communications link. ISINT will be configured for more complex links now that point-to-point performance has been validated.

Richard, Alan M.↗

NASA NTRS2001

TT and C - First TDRSS, Then Commercial GEO and Big LEO and Now through LEO

The advent of low earth orbit (LEO) commercial communications satellites provides an opportunity to dramatically reduce Telemetry Tracking and Control (TT&C) costs of launch vehicles and Unpiloted Aerial Vehicles (UAVs) by reducing or eliminating ground infrastructure. Personnel from the Goddard Space Flight Center Wallops Flight Facility (GSFC/WFF) in Virginia have successfully used commercial GEO & Big LEO communications satellites for Long Duration Balloon flight TT&C. In addition, TDRSS capability for these balloons has been developed by WFF for the Ultra Long Duration Balloons with the first test flight launch in January 2001 for one global circumnavigation at 120,000 feet altitude launched from Alice Springs. Australia. Numerous other low cost applications can new utilize the commercial LEO satellites for TT&C. The Flight Modern became a GSFC/WFF Advanced Range Technology Initiative (ARTI) in an effort to streamline TT&C capability to the user community at low cost. Phase I ground tests of The Flight Modem verified downlink communications quality of service and measured transmission latencies. These tests were completed last year, Phase II consisting of aircraft flight tests provide much of the data presented in this paper. Phase III of the Flight Modern baseline test program is a demonstration of the ruggedized version of the WFF Flight Modem flown on one sounding rocket launched from Sweden. Flights of opportunity have been and are being actively pursued with other centers, ranges and users at universities. The WFF goal is to reduce TT&C costs by providing a low cost COTS Flight Modem with a User Handbook containing system capability and limitation descriptions. Additionally, since data transmission is by packetized Internet Protocol (IP), data can be received and commands initialed from practically any location with no infrastructure. The WFF, like most ranges, has been using GPS receivers on sounding rockets and long duration balloons for several years, The WFF Flight Modem contains a GPS receiver to provide vehicle position for tracking and vehicle recovery. The system architecture which integrates antennas, GPS receiver, commercial satellite packet data modem. and a single board computer with custom software is described and a number of technical challenges are discussed along with the plan for their resolution. These include antenna development, high Doppler rates, reliability, environmental ruggedness, hand over between satellites and data security. An aggressive test plan is included which in addition to environmental Testing measures bit error rate latency and antenna patterns. Additional flight tests are planned far the near future on aircraft, long duration balloons and sounding rockets and these results as well as the current status of the project arc reported. Use of the WFF Flight Modem on small satellites is also being pursued. The LEO satellite constellation altitude above 1400 km is not an obstacle because most spacecraft do not require continuous Communications. The challenge is scheduling where store and forward techniques for command are required and downlink when the communications link allows connection (above 60 percent of the time depending on the satellite altitude). Sophisticated scheduling techniques utilizing 2-line orbital element sets available on the NASA/NORAD Internet site could be implemented for rare special cases. The current 9600 baud rate of the LEO communications link may be increased With special techniques that are planned for development in the WFF Flight Modem project.

Morgan, Dwayne↗

NASA NTRS2012

DebriSat - A Planned Laboratory-Based Satellite Impact Experiment for Breakup Fragment Characterization

DebriSat is a planned laboratory ]based satellite hypervelocity impact experiment. The goal of the project is to characterize the orbital debris that would be generated by a hypervelocity collision involving a modern satellite in low Earth orbit (LEO). The DebriSat project will update and expand upon the information obtained in the 1992 Satellite Orbital Debris Characterization Impact Test (SOCIT), which characterized the breakup of a 1960 's US Navy Transit satellite. There are three phases to this project: the design and fabrication of an engineering model representing a modern, 50-cm/50-kg class LEO satellite known as DebriSat; conduction of a laboratory-based hypervelocity impact to catastrophically break up the satellite; and characterization of the properties of breakup fragments down to 2 mm in size. The data obtained, including fragment size, area ]to ]mass ratio, density, shape, material composition, optical properties, and radar cross ]section distributions, will be used to supplement the DoD fs and NASA fs satellite breakup models to better describe the breakup outcome of a modern satellite. Updated breakup models will improve mission planning, environmental models, and event response. The DebriSat project is sponsored by the Air Force fs Space and Missile Systems Center and the NASA Orbital Debris Program Office. The design and fabrication of DebriSat is led by University of Florida with subject matter experts f support from The Aerospace Corporation. The major milestones of the project include the complete fabrication of DebriSat by September 2013, the hypervelocity impact of DebriSat at the Air Force fs Arnold Engineering Development Complex in early 2014, and fragment characterization and data analyses in late 2014.

Liou, J.-C.↗

NASA NTRS2013

DebriSat - A Planned Laboratory-Based Satellite Impact Experiment for Breakup Fragment Characterizations

The goal of the DebriSat project is to characterize fragments generated by a hypervelocity collision involving a modern satellite in low Earth orbit (LEO). The DebriSat project will update and expand upon the information obtained in the 1992 Satellite Orbital Debris Characterization Impact Test (SOCIT), which characterized the breakup of a 1960 s US Navy Transit satellite. There are three phases to this project: the design and fabrication of DebriSat - an engineering model representing a modern, 60-cm/50-kg class LEO satellite; conduction of a laboratory-based hypervelocity impact to catastrophically break up the satellite; and characterization of the properties of breakup fragments down to 2 mm in size. The data obtained, including fragment size, area-to-mass ratio, density, shape, material composition, optical properties, and radar cross-section distributions, will be used to supplement the DoD s and NASA s satellite breakup models to better describe the breakup outcome of a modern satellite.

Liou, Jer-Chyi↗

NASA NTRSDate not supplied

Environmental Control and Life Support (ECLS) System Options for Mars Transit and Mars Surface Missions

The NASA led Artemis campaign will take humanity back to the Moon and serve as an analog for continued deep space exploration to Mars. Artemis utilizes crewed vehicles and habitats on both the Lunar surface and in Lunar orbit. The exploration of the Lunar surface and buildup of a basecamp is meant to be a “Mars forward” approach to testing and refining new technologies and techniques for living and working far outside of Low Earth Orbit (LEO) and preparing for future Mars missions. The Lunar Surface Habitat is planned as a primary element for long duration crew habitation on the Moon and will be the primary testbed for ECLS system hardware in a partial gravity environment. The Mars Transit Habitat will be the crew vehicle for the roundtrip from Earth to Mars and spend a significant amount of time docked to the Gateway outfitting and testing its systems prior to making the first Mars mission transit. The Mars Transit Habitat will utilize closed loop ECLS system technologies while a Mars Surface Habitat could use either open loop, closed loop, or a mix of both. Better understanding the needs of both these system architectures operating for extended periods in the Lunar environment and outside LEO will help to establish the ECLS system architecture for the future Mars surface mission. There are many aspects to consider such as length of crew stay, level of autonomy and dormancy between crewed missions, power requirements, system mass, and overall system reliability and maintainability. Other considerations will include Mars gravity vs. Lunar gravity, Mars atmospheric pressure vs. hard vacuum, and possible use of in-situ resource utilization.

ECLSS↗

NASA NTRSDate not supplied

Environmental Control and Life Support (ECLS) System Options for Mars Transit and Mars Surface Missions

ECLSS↗

NASA NTRS2012

Post-Flight Characterization of Samples for the MISSE-7 Spacesuit Fabric Exposure Experiment

Six samples of pristine and dust-abraded outer layer spacesuit fabrics were included in the Materials International Space Station Experiment-7, in which they were exposed to the wake side low Earth orbit environment (LEO) on the International Space Station (ISS) for 18 months in order to determine whether abrasion by lunar dust increases radiation degradation. The fabric samples were characterized using optical microscopy, field emission scanning electron microscopy, and tensile testing before and after exposure on the ISS. Comparison of pre- and post-flight characterizations showed that wake side LEO environment darkened and reddened all six fabrics, increasing their integrated solar absorptance by 7 to 38 percent. There was a decrease in the ultimate tensile strength and elongation to failure of lunar dust abraded Apollo spacesuit fibers by a factor of four and increased the elastic modulus by a factor of two. The severity of the degradation of the fabric samples over this short exposure time demonstrates the necessity to find ways to prevent or mitigate radiation damage to spacesuits when planning extended missions to the Moon.

Gaier, James R.↗

NASA NTRS2013

Creating the Deep Space Environment for Testing the James Webb Space Telescope (JWST) at NASA Johnson Space Center's Chamber A

Chamber A is the largest thermal vacuum chamber at the Johnson Space Center and is one of the largest space environment chambers in the world. The chamber is 19.8 m (65 ft) in diameter and 36.6 m (120 ft) tall and is equipped with cryogenic liquid nitrogen panels (shrouds) and gaseous helium shrouds to create a simulated space environment. It was originally designed and built in the mid 1960 s to test the Apollo Command and Service Module and several manned tests were conducted on that spacecraft, contributing to the success of the program. The chamber has been used since that time to test spacecraft active thermal control systems, Shuttle DTO, DOD, and ESA hardware in simulated Low Earth Orbit (LEO) conditions. NASA is now moving from LEO towards exploration of locations with environments approaching those of deep space. Therefore, Chamber A has undergone major modifications to enable it to simulate these deeper space environments. Environmental requirements were driven, and modifications were funded by the James Webb Space Telescope program, and this telescope which will orbit Solar/Earth L2, will be the first test article to benefit from the chamber s new capabilities. To accommodate JWST, the Chamber A high vacuum system has been modernized, additional LN2 shrouds have been installed, the liquid nitrogen system has been modified to remove dependency on electrical power and increase its reliability, a new helium shroud/refrigeration system has been installed to create a colder more stable and uniform heat sink, and the controls have been updated to increase the level of automation and improve operator interfaces. Testing of these major modifications was conducted in August of 2012 and this initial test was very successful, with all major systems exceeding their performance requirements. This paper will outline the changes in overall environmental requirements, discuss the technical design data that was used in the decisions leading to the extensive modifications, and describe the new capabilities of the chamber.

Homan, Jonathan L.↗

NASA NTRS2013

Creating the Deep Space Environment for Testing the James Webb Space Telescope at NASA Johnson Space Center's Chamber A

Chamber A is the largest thermal vacuum chamber at the Johnson Space Center and is one of the largest space environment chambers in the world. The chamber is 19.8 m (65 ft.) in diameter and 36.6 m (120 ft.) tall and is equipped with cryogenic liquid nitrogen panels (shrouds) and gaseous helium shrouds to create a simulated space environment. It was originally designed and built in the mid 1960 s to test the Apollo Command and Service Module and several manned tests were conducted on that spacecraft, contributing to the success of the program. The chamber has been used since that time to test spacecraft active thermal control systems, Shuttle DTO, DOD, and ESA hardware in simulated Low Earth Orbit (LEO) conditions. NASA is now moving from LEO towards exploration of locations with environments approaching those of deep space. Therefore, Chamber A has undergone major modifications to enable it to simulate these deeper space environments. Environmental requirements were driven, and modifications were funded by the James Webb Space Telescope program, and this telescope, which will orbit Solar/Earth L2, will be the first test article to benefit from the chamber s new capabilities. To accommodate JWST, the Chamber A high vacuum system has been modernized, additional LN2 shrouds have been installed, the liquid nitrogen system has been modified to minimize dependency on electrical power and increase its reliability, a new helium shroud/refrigeration system has been installed to create a colder more stable and uniform heat sink, and the controls have been updated to increase the level of automation and improve operator interfaces. Testing of these major modifications was conducted in August of 2012 and this initial test was very successful, with all major systems exceeding their performance requirements. This paper will outline the changes in overall environmental requirements, discuss the technical design data that was used in the decisions leading to the extensive modifications, and describe the new capabilities of the chamber.

Homan, Jonathan L.↗

NASA NTRS1986

Earth vicinity trades and options

The options for recovering a returned manned Mars spacecraft are surveyed. Earth parking orbits from libration point to low circular are discussed, with a 500 km perigee, 24 hour period elliptical orbit chosen as a baseline for further calculation. Several techniques for recovering up to 100 metric tons of returned spacecraft are investigated, including recovery by a low Earth orbit (LEO) based orbit transfer vehicle (OTV) pushing the spacecraft to LEO, and OTV transporting and aerobrake to the spacecraft, and an OTV delivering propellant to the spacecraft. Methods utilizing OTVs results in less total mass in LEO, but may not be the minimum cost solutions if significant development and testing are required.

William R Stump↗

NASA NTRS1991

Debris mapping sensor technology project summary: Technology flight experiments program area of the space platforms technology program

The topics presented are covered in viewgraph form. Programmatic objectives are: (1) to improve characterization of the orbital debris environment; and (2) to provide a passive sensor test bed for debris collision detection systems. Technical objectives are: (1) to study LEO debris altitude, size and temperature distribution down to 1 mm particles; (2) to quantify ground based radar and optical data ambiguities; and (3) to optimize debris detection strategies.

Source record↗

NASA NTRS2016

The NASA/AFRL Meter Class Autonomous Telescope

For the past decade, the NASA Orbital Debris Program Office (ODPO) has relied on using various ground-based telescopes in Chile to acquire statistical survey data as well as photometric and spectroscopic data of orbital debris in geosynchronous Earth orbit (GEO). The statistical survey data have been used to supply the Orbital Debris Engineering Model (ORDEM) v.3.0 with debris detections in GEO to better model the environment at altitudes where radar detections are limited. The data produced for the statistical survey ranged from 30 to 40 nights per year, which only accounted for ~10% of the possible observing time. Data collection was restricted by ODPO resources and weather conditions. In order to improve the statistical sampling in GEO, as well as observe and sample other orbits, NASA's ODPO with support from the Air Force Research Laboratory (AFRL), has constructed a new observatory dedicated to orbital debris - the Meter Class Autonomous Telescope (MCAT) on Ascension Island. This location provides MCAT with the unique ability to access targets orbiting at an altitude of less than 1,000 km and low inclinations (< 20 deg). This orbital regime currently has little to no coverage by the U.S. Space Surveillance Network. Unlike previous ODPO optical assets, the ability to operate autonomously will allow rapid response observations of break-up events, an observing mode that was only available via radar tasking prior to MCAT's deployment. The primary goal of MCAT is to statistically characterize GEO via daily tasking files uploaded from ODPO. These tasking files define which operating mode to follow, providing the field center, rates, and/or targets to observe over the entire observing period. The system is also capable of tracking fast-moving targets in low Earth orbit (LEO), middle Earth orbit (MEO), as well as highly eccentric orbits like geostationary transfer orbits. On 25 August 2015, MCAT successfully acquired scientific first light, imaging the Bug Nebula and tracked objects in LEO, MEO, and GEO. NASA is working towards characterizing the system and thoroughly testing the integrated hardware and software control to achieve fully autonomous operations by late 2016. This paper will review the history and current status of the MCAT project, the details of the telescope system, and its five currently manifested operating modes.

Cowardin, H.↗

NASA NTRSDate not supplied

BioSentinel: To the Moon or Beyond?

BioSentinel, an Artemis-1 secondary spacecraft, will carry a biology experiment into deep space for the first time in 50 years. A 6U CubeSat form factor was utilized for the spacecraft and included technologies newly developed or adapted for operations beyond Earth orbit. This is the maiden deep-space voyage for the radio, propulsion system, electrical power system, and BioSensor payload. The spacecraft carries onboard budding yeast, Saccharomyces cerevisiae, as an analog to human cells to test the biological response to deep space radiation. Flying a secondary payload beyond LEO comes with unique challenges with respect to trajectory uncertainty and mission operations planning. BioSentinel does not carry propulsion for trajectory maneuvers, so plans for Comms and Power need to be developed for all trajectories. The nominal plan is a lunar flyby followed by an insertion into Heliocentric orbit. However, some possible scenarios include lunar eclipses that could severely impact the power budget during that phase of the mission, while others could result in a “Retrograde” hyperbola at swingby resulting in the spacecraft traveling inward toward Earth or even towards a collision with the lunar surface. BioSentinel’s final trajectory will not be known until after launch and deployment so possible scenarios need to be planned for ahead of time. This paper discusses the operational scenarios that were planned for as well as the actual execution of the mission operations including: command pass scheduling with the Deep Space Network, selecting bandwidth limits, medium gain antenna versus low gain antenna usage, and conserving power prior to a lunar eclipse. Note: Artemis-1 is planned to launch in the Spring of 2022

BioSentinel↗

NASA NTRS2012

Creating the Deep Space Environment for Testing the James Webb Space Telescope at the Johnson Space Center's Chamber A

Chamber A is the largest thermal vacuum chamber at the Johnson Space Center and is one of the largest space environment chambers in the world. The chamber is 19.8 m (65 ft) in diameter and 36.6 m (120 ft) tall and is equipped with cryogenic liquid nitrogen panels (shrouds) and gaseous helium shrouds to create a simulated space environment. It was originally designed and built in the mid 1960's to test the Apollo Command and Service Module and several manned tests were conducted on that spacecraft, contributing to the success of the program. The chamber has been used since that time to test spacecraft active thermal control systems, Shuttle DTO, DOD, and ESA hardware in simulated Low Earth Orbit (LEO) conditions. NASA is now moving from LEO towards exploration of locations with environments approaching those of deep space. Therefore, Chamber A has undergone major modifications to enable it to simulate these deeper space environments. Environmental requirements were driven, and the modifications were funded, by the James Webb Space Telescope program, and this telescope which will orbit Solar/Earth L2, will be the first test article to benefit from the chamber s new capabilities. To accommodate JWST, the Chamber A high vacuum system has been modernized, additional LN2 shrouds have been installed, the liquid nitrogen system has been modified to remove dependency on electrical power and increase its reliability, a new helium shroud/refrigeration system has been installed to create a colder more stable and uniform heat sink and, the controls have been updated to increase the level of automation and improve operator interfaces. Testing of these major modifications was conducted in August 2012 and this initial test was very successful, with all major systems exceeding their performance requirements. This paper will outline the changes in the overall environmental requirements, discuss the technical design data that was used in the decisions leading to the extensive modifications, and describe the new capabilities of the chamber.

Homan, Jonathan L.↗

NASA NTRS2006

The TPS Advanced Development Project for CEV

The CEV TPS Advanced Development Project (ADP) is a NASA in-house activity for providing two heatshield preliminary designs (a Lunar direct return as well as a LEO only return) for the CEV, including the TPS, the carrier structure, the interfaces and the attachments. The project s primary objective is the development of a single heatshield preliminary design that meets both Lunar direct return and LEO return requirements. The effort to develop the Lunar direct return capable heatshield is considered a high risk item for the NASA CEV development effort due to the low TRL (approx. 4) of the candidate TPS materials. By initiating the TPS ADP early in the development cycle, the intent is to use materials analysis and testing in combination with manufacturing demonstrations to reduce the programmatic risk of using advanced TPS technologies in the critical path for CEV. Due to the technical and schedule risks associated a Lunar return heatshield, the ADP will pursue a parallel path design approach, whereby a back-up TPS/heatshield design that only meets LEO return requirements is also developed. The TPS materials and carrier structure design concept selections will be based on testing, analysis, design and evaluation of scalability and manufacturing performed under the ADP. At the TPS PDR, the preferred programmatic strategy is to transfer the continued (detailed) design, development, testing and evaluation (DDT&E) of both the Lunar direct and LEO return designs to a government/prime contractor coordinated sub-system design team. The CEV prime contractor would have responsibility for the continued heatshield sub-system development. Continued government participation would include analysis, testing and evaluation as well as decision authority at TPS Final System Decision (FSD) (choosing between the primary and back-up heatshields) occurring between TPS PDR and TPS Critical Design Review (CDR). After TPS FSD the prime CEV contractor will complete the detailed design, certification testing, procurement, and integration of the CEV TPS.

Reuther, James↗

NASA NTRS1986

Voltage-temperature charge verification testing of 34 ampere-hour nickel-cadmium cells

This testing was designed to evaluate various voltage-temperature (V-T) charge curves for use in low-Earth-orbit (LEO) applications of nickel-cadmium battery cells. The trends established relating V-T level to utilizable capacity were unexpected. The trends toward lower capacity at higher V-T levels was predominant in this testing. This effect was a function of the V-T level, the temperature, and the cell history. This effect was attributed to changes occurring in the positive plate. The results imply that for some applications, the use of even lower V-T levels may be warranted. The need to limit overcharge, especially in the early phases of missions, is underlined by this test program.

Timmerman, P. J.↗

NASA NTRS1987

KOH concentration effect on cycle life of nickel-hydrogen cells

A cycle life test of Ni/H2 cells containing electrolytes of various KOH concentrations and a sintered type nickel electrode was carried out at 23 C using a 45 min accelerated low Earth orbit (LEO) cycle regime at 80 percent depth of discharge. One of three cells containing 26 percent KOH has achieved over 28,000 cycles, and the other two 19,000 cycles, without a sign of failure. Two other cells containing 31 percent KOH electrolyte, which is the concentration presently used in aerospace cells, failed after 2,979 and 3,620 cycles. This result indicates that the cycle life of the present type of Ni/H2 cells may be extended by a factor of 5 to 10 simply by lowering the KOH concentration. Long cycle life of a Ni/H2 battery at high depth-of-discharge operation is desired, particularly for an LEO spacecraft application. Typically, battery life of about 30,000 cycles is required for a five year mission in an LEO. Such a cycle life with presently available cells can be assured only at a very low depth-of-discharge operation. Results of testing already show that the cycle life of an Ni/H2 cell is tremendously improved by simply using an electrolyte of low KOH concentration.

Lim, Hong S.↗