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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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NASA NTRS2019

Orion Heat Shield Manufacturing Producibility Improvements for the EM-1 Flight Test Program

This paper describes how the Orion program is incorporating improvements in the heat shield design and manufacturing processes reducing programmatic risk and ensuring crew safety in support of NASA’s Exploration Missions. The Orion program successfully completed the EFT-1 flight test in 2014 and is currently developing the EM-1 spacecraft to meet the test objectives of an orbital mission to the moon and return to earth in 2019. Lessons learned from the EFT-1 manufacturing and flight test experience are being incorporated into a wide variety of vehicle systems and manufacturing processes to reduce risk to the Orion missions and flight crew. A critical contributor to crew safety is the heat shield that protects the crew capsule during re-entry through the earth’s atmosphere for return from deep space. The first flight test vehicle, EFT-1, was manufactured and tested in the Neil Armstrong Operations and Checkout (O&C) facility at KSC to demonstrate early risk reduction including the functionality of the Thermal Protection Systems (TPS) for capsule safe return to earth. The approach for the EFT-1 heat shield utilized a low risk approach using Apollo heritage design and manufacturing processes using an Avcoat TPS ablator with a honeycomb substrate to provide a one piece heat shield to meet the mission re-entry heating environments. The manufacturing processes used honeycomb cell injection guns which were redeveloped from the Apollo Lunar Program processes to build the EFT-1 heat shield. The completed heat shield was transported across the country by aircraft to the O&C at KSC for installation onto the capsule. The EFT-1 heat shield successfully performed its mission and experienced ~80% of the re-entry velocity (50% heating rate) for a lunar return for an Exploration Mission. The second flight test vehicle is the EM-1 mission which will have additional flight systems installed to fly to the moon and return. Heat shield design and producibility improvements have been incorporated in the EM-1 vehicle to meet deep space mission and programmatic requirements. The design continues to use the Avcoat material, but in a “block” configuration to enable improvements in the application processes as well as additional improvements in the carrier structure design and manufacturing operations. Incorporating flight test results and producibility improvements from EFT-1 for the heat shield system design and processes have improved the thermal protection capability, improved the producibility, and cost for EM-1 flight test.

Producibility↗
NASA NTRS1982

Comparison of evolving photovoltaic and nuclear power systems for earth orbital applications

Photovoltaic and fission reactor orbital power systems are compared in terms of the end-to-end system power-to-mass ratios. Three PV systems are examined, i.e., a solid substrate with a cell array and a NiCd battery, a modified SEP array and an NiH2 battery, and a 62-micron Si cell array and a fuel cell. All arrays were modeled to be 13.5% efficient and to produce 25 kW dc. The SP-100 reactor consists of the heat source, radiation shield, heat pipes to transfer thermal energy from the reactor to thermoelectric elements, and a waste heat radiator. Consideration is given to system applications in orbits ranging from LEO to GEO, and to mission durations of 1, 5, and 10 yr. PV systems are concluded to be flight-proven, useful out of radiation belts, and best for low to moderate power levels. Limitations exist for operations where atmospheric drag may become a factor and due to the size of a large PV power supply. Space nuclear reactors will continue under development and uses at high power levels and in low altitude orbits are foreseen.

Rockey, D. E.↗
NASA NTRS1999

Prediction and Measurement of X-Ray Spectral and Intensity Distributions from Low Energy Electron Impact Sources

In-vacuum electron beam welding is a technology that NASA considered as a joining technique for manufacture of space structures. The interaction of energetic electrons with metal produces x-rays. The radiation exposure to astronauts performing the in-vacuum electron beam welding must be characterized and minimized to insure safe operating conditions. This investigation characterized the x-ray environment due to operation of an in-vacuum electron beam welding tool. NASA, in a joint venture with the Russian Space Agency, was scheduled to perform a series of welding in space experiments on board the United States Space Shuttle. This series of experiments was named the International Space Welding Experiment (ISWE). The hardware associated with the ISWE was leased to NASA, by the Paton Welding Institute (PWI) in Ukraine, for ground based welding experiments in preparation for flight. Two tests were scheduled, using the ISWE electron beam welding tool, to characterize the radiation exposure to an astronaut during the operation of the ISWE. These radiation exposure tests consisted of Thermoluminescence Dosimeters (TLD's) shielded with material currently used by astronauts during Extra Vehicular Activities (EVA) and exposed to x-ray radiation generated by operation of an in-vacuum electron beam welding tool. This investigation was the first known application of TLD's to measure absorbed dose from x-rays of energy less than 10 KeV. The ISWE hardware was returned to Ukraine before the issue of adequate shielding for the astronauts was verified. Therefore, alternate experimental and analytical methods were developed to measure and predict the x-ray spectral and intensity distribution generated by electron impact with metal. These x-ray spectra were used to calculate the absorbed radiation dose to astronauts. These absorbed dose values were compared to TLD measurements obtained during actual operation of the in-vacuum electron beam welding tool. The calculated absorbed dose values were found to be in good agreement with the TLD values.

Edwards, David L.↗
NASA NTRS1981

Large area sheet task: Advanced dendritic web growth development

The growth of silicon dendritic web for photovoltaic applications was investigated. The application of a thermal model for calculating buckling stresses as a function of temperature profile in the web is discussed. Lid and shield concepts were evaluated to provide the data base for enhancing growth velocity. An experimental web growth machine which embodies in one unit the mechanical and electronic features developed in previous work was developed. In addition, evaluation of a melt level control system was begun, along with preliminary tests of an elongated crucible design. The economic analysis was also updated to incorporate some minor cost changes. The initial applications of the thermal model to a specific configuration gave results consistent with experimental observation in terms of the initiation of buckling vs. width for a given crystal thickness.

Duncan, C. S.↗
NASA NTRS2014

Hexavalent Chrome Free Coatings for Electronics; Electromagnetic Interference (EMI) Shielding Effectiveness (SE)

The purpose of this testing is to determine the suitability of trivalent chromium conversion coatings that meet the requirements of MIL-DTL-5541, Type II, for use in applications where high-frequency electrical performance is important. This project will evaluate the ability of coated aluminum to form adequate EMI seals. Testing will assess performance of the trivalent chromium coatings against the known control hexavalent chromium MIL-DTL-5541 Type I Class 3 before and after they have been exposed to a set of environmental conditions. Performance will be assessed by evaluating shielding effectiveness (SE) test data from a variety of test samples comprised of different aluminum types and/or conversion coatings.

hexavalent chrome↗
NASA NTRS1992

Development and application of a 3-D geometry/mass model for LDEF satellite ionizing radiation assessments

A computer model of the three dimensional geometry and material distributions for the LDEF spacecraft, experiment trays, and, for selected trays, the components of experiments within a tray was developed for use in ionizing radiation assessments. The model is being applied to provide 3-D shielding distributions around radiation dosimeters to aid in data interpretation, particularly in assessing the directional properties of the radiation exposure. Also, the model has been interfaced with radiation transport codes for 3-D dosimetry response predictions and for calculations related to determining the accuracy of trapped proton and cosmic ray environment models. The methodology is described used in developing the 3-D LDEF model and the level of detail incorporated. Currently, the trays modeled in detail are F2, F8, and H12 and H3. Applications of the model which are discussed include the 3-D shielding distributions around various dosimeters, the influence of shielding on dosimetry responses, and comparisons of dose predictions based on the present 3-D model vs those from 1-D geometry model approximations used in initial estimates.

Colborn, B. L.↗
NASA NTRS1991

Design of lightning protection for a full-authority digital engine control

The steps and procedures are described which are necessary to achieve a successful lightning-protection design for a state-of-the-art Full-Authority Digital Engine Control (FADEC) system. The engine and control systems used as examples are fictional, but the design and verification methods are real. Topics discussed include: applicable airworthiness regulation, selection of equipment transient design and control levels for the engine/airframe and intra-engine segments of the system, the use of cable shields, terminal-protection devices and filter circuits in hardware protection design, and software approaches to minimize upset potential. Shield terminations, grounding, and bonding are also discussed, as are the important elements of certification and test plans, and the role of tests and analyses. Also included are examples of multiple-stroke and multiple-burst testing. A review of design pitfalls and challenges, and status of applicable test standards such as RTCA DO-160, Section 22, are presented.

Dargi, M.↗
NASA NTRS1998

Fabrication and Resistivity of IBr Intercalated Vapor-Grown Carbon Fiber Composites

Composites using vapor-crown carbon fibers (VGCF), the most conductive of the carbon fiber types, are attractive for applications where low density, high strength, and at least moderate conductivity are required, such as electromagnetic interference shielding covers for spacecraft. The conductivity can be enhanced another order of magnitude by intercalation of the VGCF. If a high Z intercalate is used, the protection of components from ionizing radiation can be enhanced also. Thus, the intercalation of VGCF with IBr is reported. Since composite testing is required to verify properties, the intercalation reaction optimization, stability of the intercalation compound, scale-up of the intercalation reaction, composite fabrication, and resistivity of the resulting composites is also reported. The optimum conditions for low resistivity and uniformity for the scaled up reaction (20-30 g of product) were 114 C for at least 72 hr, yielding a fiber with a resistivity of 8.7+/-2 micro-Omega-cm. The thermal stability of these fibers was poor, with degradation occurring at temperatures as low as 40 C in air, though they were insensitive to water vapor. Composite resistivity was 20-30 micro-Omega-cm, as measured by contactless conductivity measurements, about a factor of five higher than would be expected from a simple rule of mixtures. The addition of 1.0 percent Br2, intercalated microfibers increased the resistivity of the composites by more than 20 percent.

Gaier, James R.↗
NASA NTRS2000

Finite Element Analysis of Reverberation Chambers

The primary motivating factor behind the initiation of this work was to provide a deterministic means of establishing the validity of the statistical methods that are recommended for the determination of fields that interact in -an avionics system. The application of finite element analysis to reverberation chambers is the initial step required to establish a reasonable course of inquiry in this particularly data-intensive study. The use of computational electromagnetics provides a high degree of control of the "experimental" parameters that can be utilized in a simulation of reverberating structures. As the work evolved there were four primary focus areas they are: 1. The eigenvalue problem for the source free problem. 2. The development of a complex efficient eigensolver. 3. The application of a source for the TE and TM fields for statistical characterization. 4. The examination of shielding effectiveness in a reverberating environment. One early purpose of this work was to establish the utility of finite element techniques in the development of an extended low frequency statistical model for reverberation phenomena. By employing finite element techniques, structures of arbitrary complexity can be analyzed due to the use of triangular shape functions in the spatial discretization. The effects of both frequency stirring and mechanical stirring are presented. It is suggested that for the low frequency operation the typical tuner size is inadequate to provide a sufficiently random field and that frequency stirring should be used. The results of the finite element analysis of the reverberation chamber illustrate io-W the potential utility of a 2D representation for enhancing the basic statistical characteristics of the chamber when operating in a low frequency regime. The basic field statistics are verified for frequency stirring over a wide range of frequencies. Mechanical stirring is shown to provide an effective frequency deviation.

Bunting, Charles F.↗
NASA NTRS2007

Model for Cumulative Solar Heavy Ion Energy and LET Spectra

A probabilistic model of cumulative solar heavy ion energy and lineary energy transfer (LET) spectra is developed for spacecraft design applications. Spectra are given as a function of confidence level, mission time period during solar maximum and shielding thickness. It is shown that long-term solar heavy ion fluxes exceed galactic cosmic ray fluxes during solar maximum for shielding levels of interest. Cumulative solar heavy ion fluences should therefore be accounted for in single event effects rate calculations and in the planning of space missions.

Xapsos, Mike↗
NASA NTRS2013

Impact-Actuated Digging Tool for Lunar Excavation

NASA s plans for a lunar outpost require extensive excavation. The Lunar Surface Systems Project Office projects that thousands of tons of lunar soil will need to be moved. Conventional excavators dig through soil by brute force, and depend upon their substantial weight to react to the forces generated. This approach will not be feasible on the Moon for two reasons: (1) gravity is 1/6th that on Earth, which means that a kg on the Moon will supply 1/6 the down force that it does on Earth, and (2) transportation costs (at the time of this reporting) of $50K to $100K per kg make massive excavators economically unattractive. A percussive excavation system was developed for use in vacuum or nearvacuum environments. It reduces the down force needed for excavation by an order of magnitude by using percussion to assist in soil penetration and digging. The novelty of this excavator is that it incorporates a percussive mechanism suited to sustained operation in a vacuum environment. A percussive digger breadboard was designed, built, and successfully tested under both ambient and vacuum conditions. The breadboard was run in vacuum to more than 2..times the lifetime of the Apollo Lunar Surface Drill, throughout which the mechanism performed and held up well. The percussive digger was demonstrated to reduce the force necessary for digging in lunar soil simulant by an order of magnitude, providing reductions as high as 45:1. This is an enabling technology for lunar site preparation and ISRU (In Situ Resource Utilization) mining activities. At transportation costs of $50K to $100K per kg, reducing digging forces by an order of magnitude translates into billions of dollars saved by not launching heavier systems to accomplish excavation tasks necessary to the establishment of a lunar outpost. Applications on the lunar surface include excavation for habitats, construction of roads, landing pads, berms, foundations, habitat shielding, and ISRU.

Wilson, Jak↗
NASA NTRS2018

Development of the Electrostatic Precipitator (ESP) for Mars and Electrodynamic Dust Shield (EDS)

Kennedy Space Center's Swamp Works is a fast-paced and diverse technology development laboratory that aims to advance commercial and government capabilities to colonize extraterrestrial environments. As a part of Swamp Works, the Electrostatic and Surface Physics Laboratory (ESPL) is currently developing new technologies that will further NASA's capabilities to colonize lunar and Martian environments. At the ESPL, the objective of the overall project is to aid in the dust mitigation of robotic and human exploration missions to the moon and Mars. The moon and Mars are covered with layers of dust, which can make long-term exploration missions very difficult. The team at the ESPL is developing an electrostatic precipitator (ESP) to aid in the reduction of interference from airborne Martian dust on equipment. The ESP is designed to mitigate the dust in an intake of CO2-rich dusty gas (i.e., the Martian atmosphere). The ESP is essentially a cylindrical tube with a coaxial wire electrode. Applying a high voltage through this electrode induces a corona discharge (a glowing plasma that envelops the electrode), which is used to charge the inflowing dust. The electric field caused by the corona pushes the charged dust to the walls of the precipitator, preventing the dust to flow out of the tube. Environmental dust can make long-term exploration missions very difficult, and settled dust is no exception. Settled lunar or Martian dust can hinder the performance and lifetime of equipment. For example, dust can settle on the solar panels of a lunar or Martian rover, decreasing its performance while increasing its charging time. To address this, the team at the ESPL is also developing an electrodynamic dust shield (EDS), which is designed to remove lunar or Martian dust from the surfaces of equipment. The EDS uses a non-uniform electric field to generate a dielectrophoretic force, which pushes the particles away from the surface of the shield. A number of dust shields will be tested on the exterior of the International Space Station (ISS) via MISSE-11, a flight payload to the ISS that will test the effects of long-term exposure to space on materials. During my internship at the ESPL, I aided in the development of these technologies. For the ESP, I helped characterize the electrical properties of various geometries and helped redesign the hardware of the testbed (the precipitator used to test this technology in the lab). To characterize the electrical properties of the ESP, I ran various tests of the precipitator, which consisted of varying the environmental conditions and geometry of the testbed. Analyzing the electrical properties of the ESP in various environmental conditions is necessary to characterize its collection efficiency, since it will be used in the dusty Martian environment. For the EDS, I helped analyze the dielectric strength of the surface of the shield via high-voltage testing. A dielectrically strong surface will help the shield survive the harsh environment of space, which will enable it to have both lunar and Martian applications.

Corona Discharge↗
NASA NTRS2018

Extreme Environments Solar Power Project Enabling Solar Array Power To The Outer Planets

NASA missions such as DAWN and JUNO, as well as the planned Europa Clipper mission, rely on solar power despite their destination's extreme distance from the Sun and the high radiation environment typically encountered. This reliance on off-the-shelf state of the art solar cells has impacted mission design and ultimate performance, as solar cells designed for 1AU space applications suffer from low intensity, low temperature (LILT) performance effects and limited radiation tolerance has required additional shielding or overdesign in order to maintain EOL performance. While reasons for the performance degradation are reasonably well understood and solutions have been proposed, the lack of a continuous mission pull for improved performance has made a dedicated project to address these issues unpractical in the past. However, with NASA embarking on the Europa Clipper mission in the next decade and a recognition that improvements to radiation tolerance positively impact all space missions; NASA's Space Technology Mission Directorate has initiated a project to develop advanced solar cells that are more efficient under LILT conditions and solar array concepts, such as concentrator systems, that improve overall performance under both LILT and high radiation conditions.

McNatt, Jeremiah↗
NASA NTRSDate not supplied

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗
NASA NTRS1972

An empirical model of energetic solar proton fluxes with applications to earth orbiting spacecraft

An empirical model for energetic solar proton fluxes is presented. With this model, the effects of such protons on geocentric space missions, to be flown during the next solar active period (1966-1983) and with orbits involving partial magnetospheric shielding, may be estimated. A synoptic background review is given, followed by a detailed discussion of the model's analytic development. Also given are comments on the model's use, errors, uncertainties, and limitations, including sample calculations which demonstrate the application of specific or general project missions. Finally, for circular trajectories, percentage exposure maps are presented, depicting fractional mission times spent outside particular L-shells as functions of orbit altitude and inclination.

Stassinopoulos, E. G.↗
NASA NTRS2001

Absorbed Dose Determination Using Experimental and Analytical Predictions of X-Ray Spectra

Electron beam welding in a vacuum is a technology that NASA is investigating as a joining technique for manufacture of space structures. This investigation characterizes the x-ray environment due to operation of an in-vacuum electron beam welding tool and provides recommendations for adequate shielding for astronauts performing the in-vacuum electron beam welding. NASA, in a joint venture with the Russian Space Agency, was scheduled to perform a series of welding in space experiments on board the U.S. Space Shuttle. This series of experiments was named the international space welding experiment (ISWE). The hardware associated with the ISWE was leased to NASA by the Paton Welding Institute (PWI) in Ukraine for ground-based welding experiments in preparation for flight. Two ground tests were scheduled, using the ISWE electron beam welding tool, to characterize the radiation exposure to an astronaut during the operation of the ISWE. These radiation exposure tests used thermoluminescence dosimeters (TLD's) shielded with material currently used by astronauts during extravehicular activities to measure the radiation dose. The TLD's were exposed to x-ray radiation generated by operation of the ISWE in-vacuum electron beam welding tool. This investigation was the first known application of TLD's to measure absorbed dose from x rays of energy less than 10 keV. The ISWE hardware was returned to Ukraine before the issue of adequate shielding for the astronauts was completely verified. Therefore, alternate experimental and analytical methods were developed to measure and predict the x-ray spectral and intensity distribution generated by ISWE electron beam impact with metal. These x-ray spectra were normalized to an equivalent ISWE exposure, then used to calculate the absorbed radiation dose to astronauts. These absorbed dose values were compared to TLD measurements obtained during actual operation of the ISWE in-vacuum electron beam welding tool. The calculated absorbed dose values were found to be in agreement with the measured TLD values.

Edwards, D. L.↗
NASA NTRS1984

Foil Panel Mirrors for Nonimaging Applications

Large durable, lightweight mirrors made by bonding thick aluminum foil to honeycomb panels or other rigid, flat backings. Mirrors suitable for use as infrared shields, telescope doors, solar-furnance doors, advertising displays, or other reflectors that require low thermal emissivity and high specularity but do not require precise surface figure necessary for imaging.

Kuyper, D. J.↗