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At least 343 records · Page 19

Rapid Fabrication of Carbide Matrix/Carbon Fiber Composites

Composites of zirconium carbide matrix material reinforced with carbon fibers can be fabricated relatively rapidly in a process that includes a melt infiltration step. Heretofore, these and other ceramic matrix composites have been made in a chemical vapor infiltration (CVI) process that takes months. The finished products of the CVI process are highly porous and cannot withstand temperatures above 3,000 F (approx.1,600 C). In contrast, the melt-infiltration-based process takes only a few days, and the composite products are more nearly fully dense and have withstood temperatures as high as 4,350 F (approx.2,400 C) in a highly oxidizing thrust chamber environment. Moreover, because the melt- infiltration-based process takes much less time, the finished products are expected to cost much less. Fabrication begins with the preparation of a carbon fiber preform that, typically, is of the size and shape of a part to be fabricated. By use of low-temperature ultraviolet-enhanced chemical vapor deposition, the carbon fibers in the preform are coated with one or more interfacial material(s), which could include oxides. The interfacial material helps to protect the fibers against chemical attack during the remainder of the fabrication process and against oxidation during subsequent use; it also enables slippage between the fibers and the matrix material, thereby helping to deflect cracks and distribute loads. Once the fibers have been coated with the interfacial material, the fiber preform is further infiltrated with a controlled amount of additional carbon, which serves as a reactant for the formation of the carbide matrix material. The next step is melt infiltration. The preform is exposed to molten zirconium, which wicks into the preform, drawn by capillary action. The molten metal fills most of the interstices of the preform and reacts with the added carbon to form the zirconium carbide matrix material. The zirconium does not react with the underlying fibers because they are protected by the interfacial material(s). The success of the melt-infiltration step depends on interface material selection and uniform coating of the fibers, infiltration with the correct amount of carbon, and careful control of temperature and rate of heating.

Williams, Brian E.↗

NASA PEMFC Development Background and History

NASA has been developing proton-exchange-membrane (PEM) fuel cell power systems for the past decade, as an upgraded technology to the alkaline fuel cells which presently provide power for the Shuttle Orbiter. All fuel cell power systems consist of one or more fuel cell stacks in combination with appropriate balance-of-plant hardware. Traditional PEM fuel cells are characterized as flow-through, in which recirculating reactant streams remove product water from the fuel cell stack. NASA recently embarked on the development of non-flow-through fuel cell systems, in which reactants are dead-ended into the fuel cell stack and product water is removed by internal wicks. This simplifies the fuel cell power system by eliminating the need for pumps to provide reactant circulation, and mechanical water separators to remove the product water from the recirculating reactant streams. By eliminating these mechanical components, the resulting fuel cell power system has lower mass, volume, and parasitic power requirements, along with higher reliability and longer life. Four vendors have designed and fabricated non-flow-through fuel cell stacks under NASA funding. One of these vendors is considered the "baseline" vendor, and the remaining three vendors are competing for the "alternate" role. Each has undergone testing of their stack hardware integrated with a NASA balance-of-plant. Future Exploration applications for this hardware include primary fuel cells for a Lunar Lander and regenerative fuel cells for Surface Systems.

Hoberecht, Mark↗

The Advantages of Non-Flow-Through Fuel Cell Power Systems for Aerospace Applications

NASA has been developing proton-exchange-membrane (PEM) fuel cell power systems for the past decade, as an upgraded technology to the alkaline fuel cells which presently provide power for the Shuttle Orbiter. All fuel cell power systems consist of one or more fuel cell stacks in combination with appropriate balance-of-plant hardware. Traditional PEM fuel cells are characterized as flow-through, in which recirculating reactant streams remove product water from the fuel cell stack. NASA recently embarked on the development of non-flow-through fuel cell systems, in which reactants are dead-ended into the fuel cell stack and product water is removed by internal wicks. This simplifies the fuel cell power system by eliminating the need for pumps to provide reactant circulation, and mechanical water separators to remove the product water from the recirculating reactant streams. By eliminating these mechanical components, the resulting fuel cell power system has lower mass, volume, and parasitic power requirements, along with higher reliability and longer life. These improved non-flow-through fuel cell power systems therefore offer significant advantages for many aerospace applications.

Hoberecht, Mark↗

Passive Vaporizing Heat Sink

A passive vaporizing heat sink has been developed as a relatively lightweight, compact alternative to related prior heat sinks based, variously, on evaporation of sprayed liquids or on sublimation of solids. This heat sink is designed for short-term dissipation of a large amount of heat and was originally intended for use in regulating the temperature of spacecraft equipment during launch or re-entry. It could also be useful in a terrestrial setting in which there is a requirement for a lightweight, compact means of short-term cooling. This heat sink includes a hermetic package closed with a pressure-relief valve and containing an expendable and rechargeable coolant liquid (e.g., water) and a conductive carbon-fiber wick. The vapor of the liquid escapes when the temperature exceeds the boiling point corresponding to the vapor pressure determined by the setting of the pressure-relief valve. The great advantage of this heat sink over a melting-paraffin or similar phase-change heat sink of equal capacity is that by virtue of the =10x greater latent heat of vaporization, a coolant-liquid volume equal to =1/10 of the paraffin volume can suffice.

Knowles, TImothy R.↗

Thermal Vacuum Testing of a Proto-flight Miniature Loop Heat Pipe with Two Evaporators and Two Condensers

This paper describes thermal vacuum testing of a proto-flight miniature loop heat pipe (MLHP) with two evaporators and two condensers designed for future small systems applications requiring low mass, low power and compactness. Each evaporator contains a wick with an outer diameter of 6.35 mm, and each has its own integral compensation chamber (CC). Miniaturization of the loop components reduces the volume and mass of the thermal system. Multiple evaporators provide flexibility for placement of instruments that need to be maintained at the same temperature, and facilitate heat load sharing among instruments, reducing the auxiliary heater power requirement. A flow regulator is used to regulate heat dissipations between the two condensers, allowing flexible placement of radiators on the spacecraft. A thermoelectric converter (TEC) is attached to each CC for control of the operating temperature and enhancement of start-up success. Tests performed include start-up, power cycle, sink temperature cycle, high power and low power operation, heat load sharing, and operating temperature control. The proto-flight MLHP demonstrated excellent performance in the thermal vacuum test. The loop started successfully and operated stably under various evaporator heat loads and condenser sink temperatures. The TECs were able to maintain the loop operating temperature within b1K of the desired set point temperature at all power levels and all sink temperatures. The un-powered evaporator would automatically share heat from the other powered evaporator. The flow regulator was able to regulate the heat dissipation among the radiators and prevent vapor from flowing into the liquid line.

Ku, Jentung↗

Thermal Integration of a Liquid Acquisition Device into a Cryogenic Feed System

Primary objectives of this effort were to define the following: (1) Approaches for quantification of the accumulation of thermal energy within a capillary screen liquid acquisition device (LAD) for a lunar lander upper stage during periods of up to 210 days on the lunar surface, (2) techniques for mitigating heat entrapment, and (3) perform initial testing, data evaluation. The technical effort was divided into the following categories: (1) Detailed thermal modeling of the LAD/feed system interactions using both COMSOL computational fluid device and standard codes, (2) FLOW-3D modeling of bulk liquid to provide interfacing conditions for the LAD thermal modeling, (3) condensation conditioning of capillary screens to stabilize surface tension retention capability, and (4) subscale testing of an integrated LAD/feed system. Substantial progress was achieved in the following technical areas: (1) Thermal modeling and experimental approaches for evaluating integrated cryogen LAD/feed systems, at both the system and component levels, (2) reduced gravity pressure control analyses, (3) analytical modeling and testing for capillary screen conditioning using condensation and wicking, and (4) development of rapid turnaround testing techniques for evaluating LAD/feed system thermal and fluid integration. A comprehensive effort, participants included a diverse cross section of representatives from academia, contractors, and multiple Marshall Space Flight Center organizations.

Hastings, L. J.↗

Post-Test Analysis of a 10-Year Sodium Heat Pipe Life Test

High-temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, Stirling cycle heat sources; and with the resurgence of space nuclear power both as reactor heat removal elements and as radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly, long-term materials compatibility is being evaluated through the use of high-temperature life test heat pipes. Thermacore, Inc., has carried out a sodium heat pipe 10-year life test to establish long-term operating reliability. Sodium heat pipes have demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 87,000 hr (10 years) at nearly 700 C. These life test results have demonstrated the potential for high-temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability. Detailed design specifications, operating history, and post-test analysis of the heat pipe and sodium working fluid are described. Lessons learned and future life test plans are also discussed.

Rosenfeld, John H.↗

Possible Calcite and Magnesium Perchlorate Interaction in the Mars Phoenix Thermal and Evolved Gas Analyzer (TEGA)

The Mars Phoenix Lander's TEGA instrument detected a calcium carbonate phase decomposing at high temperatures (approx.700 C) from the Wicked Witch soil sample [1]. TEGA also detected a lower temperature CO2 release between 400 C and 680 C [1]. Possible explanations given for this lower temperature CO2 release include thermal decomposition of Mg or Fe carbonates, a zeolitictype desorption reaction, or combustion of organic compounds in the soil [2]. The detection of 0.6 wt % soluble perchlorate by the Wet Chemistry Laboratory (WCL) on Phoenix [3] has implications for the possibility of organic molecules in the soil. Ming et al. [4] demonstrated that perchlorates could have oxidized organic compounds to CO2 in TEGA, preventing detection of their characteristic mass fragments. Here, we propose that a perchlorate salt and calcium carbonate present in martian soil reacted to produce the 400 C - 680 C TEGA CO2 release. The parent salts of the perchlorate on Mars are unknown, but geochemical models using WCL data support the possible dominance of Mg-perchlorate salts [5]. Mg(ClO4)2 6H2O is the stable phase at ambient martian conditions [6], and breaks down at lower temperatures than carbonates giving off Cl2 and HCl gas [7,8]. Devlin and Herley [7] report two exotherms at 410-478 C and 473-533 C which correspond to the decomposition of Mg(ClO4)2.

Cannon, K. M.↗

Media Effects on Lettuce Growth in "Pillows" Designed for the VEGGIE Spaceflight Growth Chamber

VEGGIE is a prototype vegetable production unit for space designed by Orbital Technologies Corporation that is being developed to fly on the International Space Station. A modular plant rooting system "pillow" is being designed to support plant growth in VEGGIE under microgravity conditions. VEGGIE pillows are small self-contained packets of media with time-release fertilizer that can wick water passively from a root mat reservoir. Seeds are planted in pillows and the entire root system of a plant is contained as the crop develops, preventing loss into the spacecraft cabin. This study compared five media types and three lettuce cultivars in pillows growing in a VEGGIE analog environment.. Media consisted of a peat-based potting mix (Fafard #2,Conrad Fafard Inc., Agawam, MA), and a calcined clay, (arcillite, 1-2 mm sifted, Turface Proleague, Profile LLC, Buffalo Grove IL) as well as three different blends of the two, 70:30, 50:50, and 30:70. Lettuce cultivars tested were 'Sierra', a bi-colored French crisp Batavia lettuce, 'Outredgeous', a red romaine lettuce and 'Flandria', a green butter head variety. Plants were grown for 28 days, harvested, biometric data was obtained, and tissue mineral analysis was performed. For all cultivars, lettuce plants grown in the media blends were more productive than those in the individual media types. All cultivars showed bell-shaped curves in response to increases in arcillite / decreases in Fafard #2 for leaf area, fresh, and dry mass. Plants in 100% Fafard #2 and in 100% arcillite were stunted, but only those in higher levels of Fafard #2 (70% and 100%) had reduced shoot percent moisture, possibly indicating that mechanisms causing stunting differed. Variation in tissue nutrient content are consistent with this, with Mg and Mn highest in plants grown in 100% Fafard and decreasing as the concentration of arcillite increased. Color also varied with media, especially in the 'Sierra' lettuce, with plants grown in increasing levels of Fafard #2 being much more red and those in 100% arcillite almost completely green. The red-leaf cultivar 'Outredgeous' showed increasing chlorophyll (SPAD values) with increasing percentage of arcillite. In all cultivars tested it appears that a mixture of media types, usually 50:50 or 30:70 Fafard #2: arcillite, sustained healthier, more productive plants. Smaller, less productive plants in either of the individual media may indicate stress issues, however more work is needed to understand the reasons for this sub-optimal growth. This work was supported by NASA

Massa, Gioia↗

Transpiration-Cooled Spacecraft-Insulation-Repair Fasteners

Transpiration-cooled fasteners are proposed that operate like an open-loop heat pipe (self-tapping screws, bolts, and spikes) for use in on-orbit repair of thermal- insulation of a space shuttle or other spacecraft. By limiting the temperature rise of such a fastener and of the adjacent repair material and thermal protection system, the transpiration cooling would contribute to the ability of the repair to retain its strength and integrity in the high-heat-flux, oxidizing environment of reentry into the atmosphere of the Earth. A typical fastener according to the proposal would include a hollow refractory-metal, refractory-composite, or ceramic screw or bolt, the central cavity of which would be occupied by a porous refractory- metal or ceramic plug that would act as both a reservoir and a wick for a transpirant liquid. The plug dimensions, the plug material, and the sizes of the pores would be chosen in conjunction with the transpirant liquid so that (1) capillary pumping could be relied upon to transport the liquid to the heated surface, where the liquid would be vaporized, and (2) the amount of liquid would suffice for protecting against the anticipated heat flux and integrated heat load.

Camarda, Charles J.↗

NASA Tech Briefs, March 2012

The topics include: 1) Spectral Profiler Probe for In Situ Snow Grain Size and Composition Stratigraphy; 2) Portable Fourier Transform Spectroscopy for Analysis of Surface Contamination and Quality Control; 3) In Situ Geochemical Analysis and Age Dating of Rocks Using Laser Ablation-Miniature Mass Spectrometer; 4) Physics Mining of Multi-Source Data Sets; 5) Photogrammetry Tool for Forensic Analysis; 6) Connect Global Positioning System RF Module; 7) Simple Cell Balance Circuit; 8) Miniature EVA Software Defined Radio; 9) Remotely Accessible Testbed for Software Defined Radio Development; 10) System-of-Systems Technology-Portfolio-Analysis Tool; 11) VESGEN Software for Mapping and Quantification of Vascular Regulators; 12) Constructing a Database From Multiple 2D Images for Camera Pose Estimation and Robot Localization; 13) Adaption of G-TAG Software for Validating Touch and Go Asteroid Sample Return Design Methodology; 14) 3D Visualization for Phoenix Mars Lander Science Operations; 15) RxGen General Optical Model Prescription Generator; 16) Carbon Nanotube Bonding Strength Enhancement Using Metal Wicking Process; 17) Multi-Layer Far-Infrared Component Technology; 18) Germanium Lift-Off Masks for Thin Metal Film Patterning; 19) Sealing Materials for Use in Vacuum at High Temperatures; 20) Radiation Shielding System Using a Composite of Carbon Nanotubes Loaded With Electropolymers; 21) Nano Sponges for Drug Delivery and Medicinal Applications; 22) Molecular Technique to Understand Deep Microbial Diversity; 23) Methods and Compositions Based on Culturing Microorganisms in Low Sedimental Fluid Shear Conditions; 24) Secure Peer-to-Peer Networks for Scientific Information Sharing; 25) Multiplexer/Demultiplexer Loading Tool (MDMLT); 26) High-Rate Data-Capture for an Airborne Lidar System; 27) Wavefront Sensing Analysis of Grazing Incidence Optical Systems; 28) Foam-on-Tile Damage Model; 29) Instrument Package Manipulation Through the Generation and Use of an Attenuated-Fluent Gas Fold; 30) Multicolor Detectors for Ultrasensitive Long-Wave Imaging Cameras; 31) Lunar Reconnaissance Orbiter (LRO) Command and Data Handling Flight Electronics Subsystem; and 32) Electro-Optic Segment-Segment Sensors for Radio and Optical Telescopes.

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Ten Year Operating Test Results and Post-Test Analysis of a 1/10 Segment Stirling Sodium Heat Pipe, Phase III

High-temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, Stirling cycle heat sources; and with the resurgence of space nuclear power both as reactor heat removal elements and as radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly, long-term materials compatibility is being evaluated through the use of high-temperature life test heat pipes. Thermacore, Inc., has carried out a sodium heat pipe 10-year life test to establish long-term operating reliability. Sodium heat pipes have demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 87,000 hr (10 yr) at nearly 700 C. These life test results have demonstrated the potential for high-temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability. Detailed design specifications, operating history, and post-test analysis of the heat pipe and sodium working fluid are described.

Rosenfeld, John, H↗

Preparation for the Proof of Concept Flight of the Veggie Plant Growth Chamber

Veggie is a small plant growth chamber designed and built by ORBITEC that will fly to the International Space Station on SpaceX-3, scheduled for the summer of 2013. Ultimately Veggie will be used for research, education and outreach, and crew recreation. We want to demonstrate the functionality of this hardware by testing a scenario that could allow the crew to grow and consume fresh vegetables. Veggie will be collapsed and transported flat in a cargo transfer bag, and deployed on orbit, where it will be installed in an EXPRESS rack. The chamber consists of three subsystems: an LED light cap, a transparent bellows, and a root mat reservoir assembly. The bellows and flexible support arms allow the distance between plants and light cap to be adjusted for different ages and types of plants. Researchers at Kennedy Space Center and ORBITEC have been working to develop the plant growth interfaces for the proof of concept flight. We have developed a rooting pillow, consisting of a small bag containing media, time release fertilizer, seeds, and a wicking surface to conduct water from the root mat reservoir. Prototype pillows have been tested and results have influenced the design of flight pillows, which will be modified for microgravity from flight-approved materials. Several studies have been conducted selecting species and comparing media types in analog systems. Water content seems to be the most important factor differentiating media types in these small growth volumes (100 mL). Media type also influenced microbial levels on plants. Since produce sanitizing agents are not currently approved for growing food crops on orbit, plants and media types having very low microbial levels are being selected. Lettuce, mizuna, and other salad greens typically have microbial counts less than 10(exp 4) colony forming units and thus are good candidates for spaceflight. As we approach flight verification testing, we will finalize species, media selection, harvesting, and microbial sampling procedures. Next steps include testing of Veggie flight and ground hardware and associated equipment. This research was funded by NASA.

Massa, Gioia↗

Closeout Report for the Refractory Metal Accelerated Heat Pipe Life Test Activity

With the selection of a gas-cooled reactor, this heat pipe accelerated life test activity was closed out and its resources redirected. The scope of this project was to establish the long-term aging effects on Mo-44.5%Re sodium heat pipes when subjected to space reactor temperature and mass fluences. To date, investigators have demonstrated heat pipe life tests of alkali metal systems up to .50,000 hours. Unfortunately, resources have not been available to examine the effect of temperature, mass fluence, or impurity level on corrosion or to conduct post-test forensic examination of heat pipes. The key objective of this effort was to establish a cost/time effective method to systematically test alkali metal heat pipes with both practical and theoretical benefits. During execution of the project, a heat pipe design was established, a majority of the laboratory test equipment systems specified, and operating and test procedures developed. Procurements for the heat pipe units and all major test components were underway at the time the stop work order was issued. An extremely important outcome was the successful fabrication of an annular wick from Mo-5%Re screen (the single, most difficult component to manufacture) using a hot isostatic pressing technique. This Technical Publication (TP) includes specifics regarding the heat pipe calorimeter water-cooling system, vendor design for the radio frequency heating system, possible alternative calorimeter designs, and progress on the vanadium equilibration technique. The methods provided in this TP and preceding project documentation would serve as a good starting point to rapidly implement an accelerated life test. Relevant test data can become available within months, not years, and destructive examination of the first life test heat pipe might begin within 6 months of test initiation. Final conclusions could be drawn in less than a quarter of the mission duration for a long-lived, fission-powered, deep space probe.

Martin, J.↗

Thermal Performance Testing of EMU and CSAFE Liquid Cooling Garments

Future exploration missions require the development of a new liquid cooling garment (LCG) that offers greater system reliability, is more comfortable, and maximizes thermal performance. To inform the development of a future LCG a thermal performance test was conducted to evaluate three factors: (1) the effect of the thermal comfort undergarment (TCU) on tactile and thermal comfort, (2) the comparable thermal performance of an CSAFE developed engineering evaluation unit (EEU) LCG, which uses a commercial-off-the-shelf (COTS) wicking garment as the base, and (3) the performance of a torso or upper body only LCG configuration to evaluate a proposed auxiliary loop configuration. To evaluate the thermal performance of each configuration a metabolic suit test was conducted, utilizing suited subjects to generate metabolic heat by walking on a treadmill at various speeds. Three (3) test subjects of similar height and weight produced a metabolic load for five tests by either resting (300-600 BTU/hr), walking at a slow pace (1200 BTU/hr), and walking at a brisk pace (2200 BTU/hr). During the test, data was collected that would allow us to track the heat transfer to the LCG and ventilation system to determine the thermal performance of the LCG configurations. Four different test configurations were tested, with one configuration tested twice. The test results show that the CSAFE EEU LCG and EMU LCG had comparable performance. The testing also showed that an auxiliary loop LCG, sized similarly to the shirt-only configuration, should provide adequate cooling for contingency scenarios. Finally, the testing showed the previous analysis that assumed a UA deterioration from the TCU was too conservative and the TCU may prove to be acceptable for future development with additional analysis and testing.

Rhodes, Richard↗

NASA Tech Briefs, March 2013

Topics covered include: Remote Data Access with IDL Data Compression Algorithm Architecture for Large Depth-of-Field Particle Image Velocimeters Vectorized Rebinning Algorithm for Fast Data Down-Sampling Display Provides Pilots with Real-Time Sonic-Boom Information Onboard Algorithms for Data Prioritization and Summarization of Aerial Imagery Monitoring and Acquisition Real-time System (MARS) Analog Signal Correlating Using an Analog-Based Signal Conditioning Front End Micro-Textured Black Silicon Wick for Silicon Heat Pipe Array Robust Multivariable Optimization and Performance Simulation for ASIC Design; Castable Amorphous Metal Mirrors and Mirror Assemblies; Sandwich Core Heat-Pipe Radiator for Power and Propulsion Systems; Apparatus for Pumping a Fluid; Cobra Fiber-Optic Positioner Upgrade; Improved Wide Operating Temperature Range of Li-Ion Cells; Non-Toxic, Non-Flammable, -80 C Phase Change Materials; Soft-Bake Purification of SWCNTs Produced by Pulsed Laser Vaporization; Improved Cell Culture Method for Growing Contracting Skeletal Muscle Models; Hand-Based Biometric Analysis; The Next Generation of Cold Immersion Dry Suit Design Evolution for Hypothermia Prevention; Integrated Lunar Information Architecture for Decision Support Version 3.0 (ILIADS 3.0); Relay Forward-Link File Management Services (MaROS Phase 2); Two Mechanisms to Avoid Control Conflicts Resulting from Uncoordinated Intent; XTCE GOVSAT Tool Suite 1.0; Determining Temperature Differential to Prevent Hardware Cross-Contamination in a Vacuum Chamber; SequenceL: Automated Parallel Algorithms Derived from CSP-NT Computational Laws; Remote Data Exploration with the Interactive Data Language (IDL); Mixture-Tuned, Clutter Matched Filter for Remote Detection of Subpixel Spectral Signals; Partitioned-Interval Quantum Optical Communications Receiver; and Practical UAV Optical Sensor Bench with Minimal Adjustability.

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Thermal Materials Drive Professional Apparel Line

Johnson Space Center investigated phase change materials (PCMs) to use in spacesuit gloves to help maintain comfortable temperatures. Years later, Boston-based Ministry of Supply developed a dress shirt that incorporated the NASA-derived PCMs, could wick away moisture, and also control odors and bacterial growth. Deemed Apollo, the shirt performs like active wear and is available in white and oxford blue.

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