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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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331 records · Page 19

Separating Propulsive Mass and Energy for Space Applications

Initially and traditionally, space access and in-space propulsion utilized combustion and expulsion of chemical “fuels” carried on board, with performance governed by the rocket equation. These chemicals produced energy, and after combustion, constituted the propulsive mass/momentum. The best such chemicals in terms of Isp that are deemed safe engineering/mission wise are hydrogen and oxygen, producing some 450 seconds of Isp. There are more reactive chemicals, such as fluorine, which have higher Isp, but also have serious safety issues. Propulsion in atmospheres can ingest atmospheric constituents (aka “airbreathing propulsion”) which provide additional propulsive mass when heated and a component of the combustion/energy generation process. This utilization of non-stored/carried propulsive mass provides partial separation of propulsive mass and energy and produces higher Isp. The other approach to separating propulsive mass and energy is to, either on board or added from offboard, supply additional energy, such as from nuclear or solar sources. This is the approach for fission nuclear thermal and electric propulsion, which can provide an Isp in excess of 800 seconds of Isp. Other processes or in addition to thermal expansion, such as electro-magnetics, can be employed to increase exit velocity and Isp. Separating propulsive mass and energy for space faring is commonly referred to as a means to circumvent the rocket equation and is capable of producing major benefits for the development of commercial deep space and space faring in general including affordable fast transits to mitigate the human health impacts of galactic cosmic radiation (GCR) and microG. The key to higher than chemical Isp, beyond H2-O2, and beyond the radiated energy and systems limitations of solar for space faring, is a light weight, high energy density source, either on board or via utilization of energy beaming to the vehicle. Traditional energy sources include chemical, heat, electrics, mechanical, photons, and nuclear. Propulsive mass can be carried on board, sourced beyond the surface of Earth via in-situ resource utilization (ISRU), and includes harvesting from atmospheres. High Isp via electromagnetic related propulsive mass acceleration requires sufficient ionization and conductivity. The major metrics for space propulsion are costs, safety, Isp, weight, and thrust level, the latter dependent upon mission requirements. High thrust for human missions is needed to reduce time exposed to radiation and microG and high thrust is required for space access. Costs of space access are reducing via reusability, printing manufacture, and robotization of manufacturing and operation. Chemical rockets provide high thrust from the expansion of the heated mass constituents at high mass flow. The other high thrust propulsion approach is magnetohydrodynamics (MHD), which, in addition to high thrust, has a high Isp of over 2,000 seconds of Isp. The VASIMIR engine offers some 5,000 seconds of Isp at high thrust [ref. 3]. Electric propulsion cycles are capable of Isp much higher than that but at low thrust levels using available energy sources. With cost as a major metric, reusable rockets and improved manufacturing and operations are rapidly greatly lowering the costs of space access, which could provide/supply in space fuel depots and affordable chemical propulsion for the desired human fast transits (e.g., some 200-day round trips to Mars). The other option for fast transits is VASIMIR, given a nuclear on-board energy source that has the requisite many megawatts of power and an alpha, kgs of weight/kW of energy produced, on the order of one (i.e., a light weight, high energy density energy source). The purpose of this report is to examine the options beyond traditional rocket engines, where propulsive mass and energy are combined, specifically the separation of propulsive mass and energy. This report considers the spectrum of advanced energetics, sources of propulsive mass, conductivity enhancement approaches, energy beaming possibilities, and candidate propulsion cycles. Suggestions are made for various combinatorial, system level, beyond traditional combustion rocket, space propulsion approaches for human deep space missions given the changing conditions of increased knowledge of deep space resources for ISRU, revolutionary energetics, and technology advancements writ large.

Dennis M. Bushnell↗

Nuclear Thermal Propulsion (NTP) Fission Product and Source Term Analysis

Nuclear thermal propulsion (NTP) is an in-space propulsion technology that uses a nuclear reactor to directly heat a propellant to provide high thrust, at higher efficiencies than achievable with conventional chemical propulsion systems. Due to the ability of NTP rockets to efficiently provide high thrust, this technology has been proposed for long duration space missions such as crewed missions to Mars and beyond. A primary hurdle for NTP technology development is the demonstration of an integrated reactor engine system to verify its functionality and performance. This primarily requires the manufacture and testing of candidate reactor and engine technologies to demonstrate the proposed design enables desired performance and exhibits acceptable response under all known operation modes. A major component in this testing is fission product accumulation, since after operation radioactive isotopes can be produced and pose radiological dose concerns. This paper explains the background behind fission product analysis and the methodology used to evaluate current reactor designs and identify the amount of fission products present and their radiological impact. Results of multiple thrust level engines at different time periods are discussed and highlight the need for additional experimental testing to confirm fractional release levels of fission products out of the system. Benchmarking of models and future paths of analysis are also discussed.

Nuclear Thermal Propulsion↗

Hardware Autonomy for Space Infrastructure

NASA prioritizes autonomous systems development with the expectation that it will continue to drive significant improvements in human and science exploration capability. Crew operations benefit from a spectrum of machine assistance to complete replacement of dangerous or highly repetitive tasks. Many science operations have a teleoperation component, and similarly benefit from a range of autonomy implementations that make long distance applications feasible. As we consider longer duration deep space missions, we also consider higher levels of autonomy in order meet emergent safety, maintenance, and logistics needs. One of the challenges within this scope is installation and maintenance of infrastructure, such as large scale instrumentation and communications equipment, crew habitats, and operational facilities. We describe how a programmable meta-material architecture may shift the paradigm of how we design, build, and operate future space infrastructure and assets. A primary objective of this strategy is to free the design space from launch vehicle constraints and fundamentally shift how a mission is designed and conducted. This integrates advances in materials (mechanical meta-materials), manufacturing (cooperative mobile robotics), and autonomy (multi-agent planning algorithms). Engineering systems that utilize a modular and reconfiguration building block approach, such as digital communication and computation systems, currently lead in terms of size and complexity scalability. NASA is extending the benefits and flexibility of digital systems to hardware systems, to optimize materials life-cycle management and expand our space exploration mission capabilities to meet long duration and deep space infrastructure needs, in accordance with long term NASA goals of "in-space reliance" and "mass-less exploration."

In space assembly↗

MMIC-I: A Robotic Platform for Assembly Integration and Internal Locomotion through Mechanical Meta-Material Structures

In-space assembly is crucial to creating large-scale space structures and enabling long term space missions. Natural limitations in the size of transportation vehicles and ISRU production facilities necessitate an additive strategy with the size of the typical structural unit being essentially fixed and inversely proportional to the final assembly size. In prior robotic and space assembly examples, reversible mechanical integration of structural modules is typically achieved with actuated alignment and fastening mechanisms onboard every structural module. Additive assembly or manufacturing planning approaches often feature a “build front” that receives new materials or parts and progresses gradually across the target geometry. The system we describe here places much of the alignment and fastener actuation systems onboard a mobile robot that can operate at a build front while companion robots (Scaling Omni-directional Lattice Locomoting Explorer, SOLLE) provide part or material transportation. The design and evaluation of this Mobile Meta-Material Interior Co-Integrator (MMIC-I), an inchworm-style locomoting robotic assembler, is described here with an emphasis on ease of assembly and a low number of unique parts for a simple design. It is designed to assist in alignment of cuboctahedron structural unit cells with captive fasteners, defining the build front in operation. Adjacent structural unit cells are locked together with specified axial and rotational actuation of the fasteners. Hardware prototypes show that the robot is able to successfully locomote to any indexed location within a lattice structure and bolt together each set of fasteners on any interface.

Robotics↗

Precision in Assembled Discrete Lattice Space Structures for Next-Generation ISAM Applications

Robust autonomous robotic assembly of large-scale space structures has been a long-term and challenging goal to enable higher quality in-space communication and science instrumentation. For optical observatory support structures and antenna structures, the challenge is the strict dimensional precision requirements (generally RMS surface error) driven by the operational radiation wavelength. Early theoretical work in the area linked RMS surface error of a reflector support truss plate to the natural passive dynamic mode frequencies of the structure, as well as to the error distribution in dimensions of constituent structural elements. Prior robotic truss assembly demonstrations focused on designing ultra-high precision structural elements, joints, and robotic actuators. Recently, an alternative space structure assembly strategy based on a programmable matter approach (NASA ARMADAS) was demonstrated. This approach uses lattice building blocks (voxels) that are reversibly, mechanically joined into a bulk lattice structure by robots that locomote in and on the structure itself. Such a system can achieve high-level autonomy with low computation, robustly assemble utilizing inexpensive and imprecise robots, and efficiently build structures several orders of magnitude larger than the assembly robots. However, for instrumentation support structure applications, the resulting precision of these building block-based lattice structures is not well studied. Since they are demonstrated with many more assembly units than prior art trusses, it is unclear whether the same precision design approaches apply. In this work, we study in simulation the effects of voxel geometry, error in distribution, assembly resolution (module size), and assembly geometry on the error of both beam and plate lattice structures. While average RMS error of a plate increases with plate size, increasing plate thickness quickly collapses RMS error towards a limit that is on the order of the error of the constituent parts. We validate our models against previously published precision measurements of built systems. Results from this study will guide manufacturing precision requirements, as well as designs, for future robotically assembled structural applications and establish feasibility for different applications.

Christine E Gregg↗

Finite Element Thermal Model for Ultrasonic Welding of Thermoplastic Composites

Ultrasonic welding, UW, is a fast and energy-efficient technique for joining thermoplastic composites. It involves the use of high-frequency mechanical vibrations and a static welding force to melt and join adherends. Ultrasonic welding is an enabling technology to reduce the cost and complexity of in-space construction because lightweight thermoplastic composite components can be packaged compactly for launch and then efficiently assembled using supervised autonomous robotic technologies on site. However, the temperatures in space present challenges to UW, and it is critical that the efficacy of process parameters selected for manufacturing in space is understood prior to launch. To this end, a three-dimensional finite element model is presented in this technical presentation. The model incorporates equations for effects of viscoelastic heating and heat transfer on the welding process. The proposed model is applied to predict the temperature distribution in single lap shear, SLS, samples composed of AS4/PEEK (TC1200) composite that were welded using a terrestrial machine as part of a comprehensive weldability study. Thermocouple and infrared spot sensor data from the SLS samples provide empirical temperature measurements for calibration and validation of the UW thermal model. Calibration and validation of the model is an important step given the significant uncertainties in material properties such as the loss modulus and necessary assumptions in the physics implementations which allow the model to converge in an acceptable amount of time. The validated thermal model can be used to simulate the process for the space environment. Future validation sample testing is planned in a vacuum chamber. The result will be a model capable of guiding process parameter selection to ensure acceptable weld bonds when manufacturing in space.

Josh Fody↗

Technology Assessment and Modelling of Three Terminal Tandem Solar Cells for In-Space Utilization

NASA seeks a sustained human presence on the lunar surface. High-efficiency and resilient energy systems are critical to supporting habitats, scientific outposts, and lunar surface operations. Photovoltaics have long been the backbone of space power systems, transitioning from silicon solar cells to multi-junction III-V solar cells, which now dominate state-of-the-art (SOA) technology. Multi-junction cells achieve high efficiency by layering semiconductors, each absorbing a specific portion of the solar spectrum. However, efficiency gains are increasingly constrained by device physics and manufacturing complexity. Additionally, higher-order junctions pose challenges for accurate modelling and performance characterization due to difficulties in replicating the AM0 spectrum.

solar cells↗