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NASA NTRS2012

Advanced Stirling Radioisotope Generator Thermal Power Model in Thermal Desktop SINDA/FLUINT Analyzer

This paper presents a three-dimensional Advanced Stirling Radioisotope Generator (ASRG) thermal power model that was built using the Thermal Desktop SINDA/FLUINT thermal analyzer. The model was correlated with ASRG engineering unit (EU) test data and ASRG flight unit predictions from Lockheed Martin's Ideas TMG thermal model. ASRG performance under (1) ASC hot-end temperatures, (2) ambient temperatures, and (3) years of mission for the general purpose heat source fuel decay was predicted using this model for the flight unit. The results were compared with those reported by Lockheed Martin and showed good agreement. In addition, the model was used to study the performance of the ASRG flight unit for operations on the ground and on the surface of Titan, and the concept of using gold film to reduce thermal loss through insulation was investigated.

Wang, Xiao-Yen↗
NASA NTRS2015

Advanced Stirling Radioisotope Generator Engineering Unit 2 (ASRG EU2) Final Assembly

NASA Glenn Research Center (GRC) has recently completed the assembly of a unique Stirling generator test article for laboratory experimentation. Under the Advanced Stirling Radioisotope Generator (ASRG) flight development contract, NASA GRC initiated a task to design and fabricate a flight-like generator for in-house testing. This test article was given the name ASRG Engineering Unit 2 (EU2) as it was effectively the second engineering unit to be built within the ASRG project. The intent of the test article was to duplicate Lockheed Martin's qualification unit ASRG design as much as possible to enable system-level tests not previously possible at GRC. After the cancellation of the ASRG flight development project, the decision was made to continue the EU2 build, and make use of a portion of the hardware from the flight development project. GRC and Lockheed Martin engineers collaborated to develop assembly procedures, leveraging the valuable knowledge gathered by Lockheed Martin during the ASRG development contract. The ASRG EU2 was then assembled per these procedures at GRC with Lockheed Martin engineers on site. The assembly was completed in August 2014. This paper details the components that were used for the assembly, and the assembly process itself.

Stirling Cycle↗
NASA NTRS2015

NASA Glenn Research Center Support of the Advanced Stirling Radioisotope Generator Project

A high-efficiency radioisotope power system was being developed for long-duration NASA space science missions. The U.S. Department of Energy (DOE) managed a flight contract with Lockheed Martin Space Systems Company to build Advanced Stirling Radioisotope Generators (ASRGs), with support from NASA Glenn Research Center. DOE initiated termination of that contract in late 2013, primarily due to budget constraints. Sunpower, Inc., held two parallel contracts to produce Advanced Stirling Convertors (ASCs), one with Lockheed Martin to produce ASC-F flight units, and one with Glenn for the production of ASC-E3 engineering unit "pathfinders" that are built to the flight design. In support of those contracts, Glenn provided testing, materials expertise, Government-furnished equipment, inspection capabilities, and related data products to Lockheed Martin and Sunpower. The technical support included material evaluations, component tests, convertor characterization, and technology transfer. Material evaluations and component tests were performed on various ASC components in order to assess potential life-limiting mechanisms and provide data for reliability models. Convertor level tests were conducted to characterize performance under operating conditions that are representative of various mission conditions. Despite termination of the ASRG flight development contract, NASA continues to recognize the importance of high-efficiency ASC power conversion for Radioisotope Power Systems (RPS) and continues investment in the technology, including the continuation of the ASC-E3 contract. This paper describes key Government support for the ASRG project and future tests to be used to provide data for ongoing reliability assessments.

Technology Transfer↗
NASA NTRS2008

GRC Supporting Technology for NASA's Advanced Stirling Radioisotope Generator (ASRG)

From 1999 to 2006, the NASA Glenn Research Center (GRC) supported a NASA project to develop a high-efficiency, nominal 110-We Stirling Radioisotope Generator (SRG110) for potential use on NASA missions. Lockheed Martin was selected as the System Integration Contractor for the SRG110, under contract to the Department of Energy (DOE). The potential applications included deep space missions, and Mars rovers. The project was redirected in 2006 to make use of the Advanced Stirling Convertor (ASC) that was being developed by Sunpower, Inc. under contract to GRC, which would reduce the mass of the generator and increase the power output. This change would approximately double the specific power and result in the Advanced Stirling Radioisotope Generator (ASRG). The SRG110 supporting technology effort at GRC was replanned to support the integration of the Sunpower convertor and the ASRG. This paper describes the ASRG supporting technology effort at GRC and provides details of the contributions in some of the key areas. The GRC tasks include convertor extended-operation testing in air and in thermal vacuum environments, heater head life assessment, materials studies, permanent magnet characterization and aging tests, structural dynamics testing, electromagnetic interference and electromagnetic compatibility characterization, evaluation of organic materials, reliability studies, and analysis to support controller development.

Schreiber, Jeffrey G.↗
NASA NTRS2013

External Magnetic Field Reduction Techniques for the Advanced Stirling Radioisotope Generator

Linear alternators coupled to high efficiency Stirling engines are strong candidates for thermal-to-electric power conversion in space. However, the magnetic field emissions, both AC and DC, of these permanent magnet excited alternators can interfere with sensitive instrumentation onboard a spacecraft. Effective methods to mitigate the AC and DC electromagnetic interference (EMI) from solenoidal type linear alternators (like that used in the Advanced Stirling Convertor) have been developed for potential use in the Advanced Stirling Radioisotope Generator. The methods developed avoid the complexity and extra mass inherent in data extraction from multiple sensors or the use of shielding. This paper discusses these methods, and also provides experimental data obtained during breadboard testing of both AC and DC external magnetic field devices.

Thermoelectric Power Generation↗
NASA NTRS2007

Development of Advanced Stirling Radioisotope Generator for Space Exploration

Under the joint sponsorship of the Department of Energy and NASA, a radioisotope power system utilizing Stirling power conversion technology is being developed for potential future space missions. The higher conversion efficiency of the Stirling cycle compared with that of Radioisotope Thermoelectric Generators (RTGs) used in previous missions (Viking, Pioneer, Voyager, Galileo, Ulysses, Cassini, and New Horizons) offers the advantage of a four-fold reduction in PuO2 fuel, thereby saving cost and reducing radiation exposure to support personnel. With the advancement of state-of-the-art Stirling technology development under the NASA Research Announcement (NRA) project, the Stirling Radioisotope Generator program has evolved to incorporate the advanced Stirling convertor (ASC), provided by Sunpower, into an engineering unit. Due to the reduced envelope and lighter mass of the ASC compared to the previous Stirling convertor, the specific power of the flight generator is projected to increase from 3.5 to 7 We/kg, along with a 25 percent reduction in generator length. Modifications are being made to the ASC design to incorporate features for thermal, mechanical, and electrical integration with the engineering unit. These include the heat collector for hot end interface, cold-side flange for waste heat removal and structural attachment, and piston position sensor for ASC control and power factor correction. A single-fault tolerant, active power factor correction controller is used to synchronize the Stirling convertors, condition the electrical power from AC to DC, and to control the ASCs to maintain operation within temperature and piston stroke limits. Development activities at Sunpower and NASA Glenn Research Center (GRC) are also being conducted on the ASC to demonstrate the capability for long life, high reliability, and flight qualification needed for use in future missions.

Chan, Jack↗
NASA NTRS2005

Supporting Development for the Stirling Radioisotope Generator and Advanced Stirling Technology Development at NASA Glenn

A high-efficiency, 110-W(sub e) (watts electric) Stirling Radioisotope Generator (SRG110) for possible use on future NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and NASA Glenn Research Center (GRC). Potential mission use includes providing spacecraft onboard electric power for deep space missions and power for unmanned Mars rovers. GRC is conducting an in-house supporting technology project to assist in SRG110 development. One-, three-, and six-month heater head structural benchmark tests have been completed in support of a heater head life assessment. Testing is underway to evaluate the key epoxy bond of the permanent magnets to the linear alternator stator lamination stack. GRC has completed over 10,000 hours of extended duration testing of the Stirling convertors for the SRG110, and a three-year test of two Stirling convertors in a thermal vacuum environment will be starting shortly. GRC is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall generator. Sunpower, Inc. has begun the development of a lightweight Stirling convertor, under a NASA Research Announcement (NRA) award, that has the potential to double the system specific power to about 8 W(sub e) per kilogram. GRC has performed random vibration testing of a lowerpower version of this convertor to evaluate robustness for surviving launch vibrations. STC has also completed the initial design of a lightweight convertor. Status of the development of a multi-dimensional computational fluid dynamics code and high-temperature materials work on advanced superalloys, refractory metal alloys, and ceramics are also discussed.

Thieme, Lanny G.↗
NASA NTRS2005

Supporting Development for the Stirling Radioisotope Generator and Advanced Stirling Technology Development at NASA Glenn Research Center

A high-efficiency, 110-We (watts electric) Stirling Radioisotope Generator (SRG110) for possible use on future NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company (STC), and NASA Glenn Research Center (GRC). Potential mission use includes providing spacecraft onboard electric power for deep space missions and power for unmanned Mars rovers. GRC is conducting an in-house supporting technology project to assist in SRG110 development. One-, three-, and six-month heater head structural benchmark tests have been completed in support of a heater head life assessment. Testing is underway to evaluate the key epoxy bond of the permanent magnets to the linear alternator stator lamination stack. GRC has completed over 10,000 hours of extended duration testing of the Stirling convertors for the SRG110, and a three-year test of two Stirling convertors in a thermal vacuum environment will be starting shortly. GRC is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall generator. Sunpower, Inc. has begun the development of a lightweight Stirling convertor, under a NASA Research Announcement (NRA) award, that has the potential to double the system specific power to about 8 We/kg. GRC has performed random vibration testing of a lower-power version of this convertor to evaluate robustness for surviving launch vibrations. STC has also completed the initial design of a lightweight convertor. Status of the development of a multi-dimensional computational fluid dynamics code and high-temperature materials work on advanced superalloys, refractory metal alloys, and ceramics are also discussed.

Thieme, Lanny G.↗
NASA NTRS2014

System-Level Testing of the Advanced Stirling Radioisotope Generator Engineering Hardware

To support future NASA deep space missions, a radioisotope power system utilizing Stirling power conversion technology was under development. This development effort was performed under the joint sponsorship of the Department of Energy and NASA, until its termination at the end of 2013 due to budget constraints. The higher conversion efficiency of the Stirling cycle compared with that of the Radioisotope Thermoelectric Generators (RTGs) used in previous missions (Viking, Pioneer, Voyager, Galileo, Ulysses, Cassini, Pluto New Horizons and Mars Science Laboratory) offers the advantage of a four-fold reduction in Pu-238 fuel, thereby extending its limited domestic supply. As part of closeout activities, system-level testing of flight-like Advanced Stirling Convertors (ASCs) with a flight-like ASC Controller Unit (ACU) was performed in February 2014. This hardware is the most representative of the flight design tested to date. The test fully demonstrates the following ACU and system functionality: system startup; ASC control and operation at nominal and worst-case operating conditions; power rectification; DC output power management throughout nominal and out-of-range host voltage levels; ACU fault management, and system command / telemetry via MIL-STD 1553 bus. This testing shows the viability of such a system for future deep space missions and bolsters confidence in the maturity of the flight design.

Deep space↗
NASA NTRS2012

Advanced Stirling Radioisotope Generator (ASRG) Thermal Power Model in MATLAB

This paper presents a one-dimensional steady-state mathematical thermal power model of the ASRG. It aims to provide a guideline of understanding how the ASRG works and what can change its performance. The thermal dynamics and energy balance of the generator is explained using the thermal circuit of the ASRG. The Stirling convertor performance map is used to represent the convertor. How the convertor performance map is coupled in the thermal circuit is explained. The ASRG performance characteristics under i) different sink temperatures and ii) over the years of mission (YOM) are predicted using the one-dimensional model. Two Stirling converter control strategies, i) fixing the hot-end of temperature of the convertor by adjusting piston amplitude and ii) fixing the piston amplitude, were tested in the model. Numerical results show that the first control strategy can result in a higher system efficiency than the second control strategy when the ambient gets warmer or the general-purpose heat source (GPHS) fuel load decays over the YOM. The ASRG performance data presented in this paper doesn't pertain to the ASRG flight unit. Some data of the ASRG engineering unit (EU) and flight unit that are available in public domain are used in this paper for the purpose of numerical studies.

Wang, Xiao-Yen, J.↗
NASA NTRS2016

Active Vibration Reduction of the Advanced Stirling Convertor

Stirling Radioisotope Power Systems (RPS) are being developed as an option to provide power on future space science missions where robotic spacecraft will orbit, flyby, land or rove. A Stirling Radioisotope Generator (SRG) could offer space missions a more efficient power system that uses one fourth of the nuclear fuel and decreases the thermal footprint compared to the current state of the art. The Stirling Cycle Technology Development (SCTD) Project is funded by the RPS Program to developing Stirling-based subsystems, including convertors and controller maturation efforts that have resulted in high fidelity hardware like the Advanced Stirling Radioisotope Generator (ASRG), Advanced Stirling Convertor (ASC), and ASC Controller Unit (ACU). The SCTD Project also performs research to develop less mature technologies with a wide variety of objectives, including increasing temperature capability to enable new environments, improving system reliability or fault tolerance, reducing mass or size, and developing advanced concepts that are mission enabling. Active vibration reduction systems (AVRS), or "balancers", have historically been developed and characterized to provide fault tolerance for generator designs that incorporate dual-opposed Stirling convertors or enable single convertor, or small RPS, missions. Balancers reduce the dynamic disturbance forces created by the power piston and displacer internal moving components of a single operating convertor to meet spacecraft requirements for induced disturbance force. To improve fault tolerance for dual-opposed configurations and enable single convertor configurations, a breadboard AVRS was implemented on the Advanced Stirling Convertor (ASC). The AVRS included a linear motor, a motor mount, and a closed-loop controller able to balance out the transmitted peak dynamic disturbance using acceleration feedback. Test objectives included quantifying power and mass penalty and reduction in transmitted force over a range of ASC operating parameters and mounting conditions. All tests were performed at three different piston amplitudes, 3.0, 3.75, and 4.5 mm. Overall, the transmitted force was reduced to 2 percent of the total unbalanced force by actively balancing out only the first fundamental frequency, with balancer motor power remaining under 1 watt. The test results will be used to guide future balancer designs.

Balancer↗
NASA NTRS2016

Active Vibration Reduction of the Advanced Stirling Convertor

Stirling Radioisotope Power Systems (RPS) are being developed as an option to provide power on future space science missions where robotic spacecraft will orbit, flyby, land or rove. A Stirling Radioisotope Generator (SRG) could offer space missions a more efficient power system that uses one fourth of the nuclear fuel and decreases the thermal footprint compared to the current state of the art. The Stirling Cycle Technology Development (SCTD) Project is funded by the RPS Program to developing Stirling-based subsystems, including convertors and controller maturation efforts that have resulted in high fidelity hardware like the Advanced Stirling Radioisotope Generator (ASRG), Advanced Stirling Convertor (ASC), and ASC Controller Unit (ACU). The SCTD Project also performs research to develop less mature technologies with a wide variety of objectives, including increasing temperature capability to enable new environments, improving system reliability or fault tolerance, reducing mass or size, and developing advanced concepts that are mission enabling. Active vibration reduction systems (AVRS), or "balancers", have historically been developed and characterized to provide fault tolerance for generator designs that incorporate dual-opposed Stirling convertors or enable single convertor, or small RPS, missions. Balancers reduce the dynamic disturbance forces created by the power piston and displacer internal moving components of a single operating convertor to meet spacecraft requirements for induced disturbance force. To improve fault tolerance for dual-opposed configurations and enable single convertor configurations, a breadboard AVRS was implemented on the Advanced Stirling Convertor (ASC). The AVRS included a linear motor, a motor mount, and a closed-loop controller able to balance out the transmitted peak dynamic disturbance using acceleration feedback. Test objectives included quantifying power and mass penalty and reduction in transmitted force over a range of ASC operating parameters and mounting conditions. All tests were performed at three different piston amplitudes, 3.0 mm, 3.75 mm, and 4.5 mm. Overall, the transmitted force was reduced to 2% of the total unbalanced force by actively balancing out only the first fundamental frequency, with balancer motor power remaining under one watt. The test results will be used to guide future balancer designs.

Active Vibration Reduction↗
NASA NTRS2019

Maturation of Dynamic Power Convertors for Radioisotope Power Systems

Dynamic Radioisotope Power Systems (DRPS) are being developed by NASA's RPS Program in collaboration with the U.S. Department of Energy (DOE) for space science and exploration missions. A development effort is currently underway to mature dynamic power convertors for infusion into a potential future flight generator. This convertor maturation effort was formulated by the RPS Program at NASA Headquarters based on successful maturation models and utilizes expertise from agency technology and mission centers to support requirements development and technology assessments. The effort is being executed by Glenn Research Center's Dynamic Radioisotope Power Systems (DRPS) project and the Thermal Energy Conversion Branch. The Dynamic Power Convertor (DPC) contracts consist of three phases to enable design, fabrication, and independent assessment after delivery to the government. The contracts are intended to gather data on candidate dynamic conversion technologies to fill knowledge gaps, support assessments of dynamic conversion technologies, and elicit generator requirements. The SRG-110 (Stirling Radioisotope Generator) and ASRG (Advanced Stirling Radioisotope Generator) flight development projects provided Stirling convertor demonstration units and engineering models to verify and validate convertors against performance specifications and mission requirements. These units utilize temperature resistance materials and non-contacting bearings to demonstrate wear-free, long-life operation. This maturation effort builds on past lessons learned and new requirements focused on demonstrating convertor robustness to critical environments meant to stress key aspects of each convertor within the margins of the design. This effort seeks to realize the full potential of dynamic power conversion technologies for NASA's space science and exploration missions.

Wilson, Scott↗
NASA NTRS2019

Maturation of Dynamic Power Convertors for Radioisotope Power Systems

Dynamic Radioisotope Power Systems (DRPS) are being developed by NASA’s Radioisotope Power Systems (RPS) Program in collaboration with the U.S. Department of Energy (DOE) for space science and exploration missions. A development effort is currently underway to mature dynamic power convertors for infusion into a potential future flight generator. This convertor maturation effort was formulated by the RPS Program at NASA Headquarters based on successful maturation models and utilizes expertise from agency’s technology and mission centers to support requirements development and technology assessments. The effort is being executed by Glenn Research Center’s (GRC) DRPS Project and the Thermal Energy Conversion Branch. The Dynamic Power Convertor (DPC) contracts consist of three phases to enable design, fabrication, and independent assessment of prototypes after delivery to the government. The contracts are intended to gather data on candidate dynamic conversion technologies to fill knowledge gaps, support assessments of dynamic conversion technologies, and elicit generator requirements. The 110-watt Stirling Radioisotope Generator (SRG-110) and Advanced Stirling Radioisotope Generator (ASRG) flight development projects provided Stirling convertor demonstration units and engineering models to verify and validate convertors against performance specifications and mission requirements. These units utilize temperature resistant materials and non-contacting bearings to demonstrate wear-free, long-life operation. This maturation effort builds on past lessons-learned and new requirements focused on demonstrating convertor robustness to critical environments meant to stress key aspects of each convertor within the margins of the design. This effort seeks to realize the full potential of dynamic power conversion technologies for NASA’s space science and exploration missions.

Wilson, Scott↗
NASA NTRS2017

Hardware Assessment in Support of the Dynamic Power Convertor Development Effort

Stirling Radioisotope Power Systems (RPS) are being developed by NASA's RPS Program in collaboration with the U.S. Department of Energy (DOE). Efforts ranging from 2001 to 2015 enabled development of the Technology Demonstration Convertor (TDC) for use in the 110-watt Stirling Radioisotope Generator (SRG-110) and the Advanced Stirling Convertor (ASC) for use in the Advanced Stirling Radioisotope Generator (ASRG). The DOE selected Lockheed Martin Space Systems Company (LMSSC) as the system integration contractor for both flight development efforts. The SRG-110 housed two TDCs fabricated by Infinia and resulted in the production of 16x demonstration units and 2x engineering units. The project was redirected in 2006 to make use of a more efficient and lower mass ASCs under development by Sunpower Inc. The DOE managed the flight contract with LMSSC and subcontractor Sunpower Inc. from 2007 to 2013 to build the ASRG, with support from NASA Glenn Research Center (GRC). Sunpower Inc. held two parallel contracts to produce ASCs, one with Lockheed Martin to produce ASC-F flight units and one with GRC for the production of ASC-E3 engineering unit pathfinders that were used to refine the flight design and production processes. The DOE initiated termination of the ASRG contract in late 2013. After ASRG had ended, GRC completed characterization testing of the ASRG Engineering Unit #2 (EU2) and the GRC contract with Sunpower was also completed. The NASA RPS Program Office has recently initiated a new Dynamic Power Conversion development effort which includes the potential maturation of Stirling, Brayton, and Rankine power convertors for the next generation of RPS. The effort started with the request for proposal and review of submits. Contracts are anticipated for release in 2017 and will initially focus on a design phase prior to fabrication and testing. This new effort will focus on robustness in addition to high efficiency, specific power, and reliability. Also, some requirements introduced during the ASRG contract have also been included in the new effort, such as constant lateral loading. Due to the focus on robustness and new requirements relative to the older TDC design, the Stirling Cycle Development Project has initiated an assessment of government owned hardware to help inform requirements evolution and evaluation of future designs. While lessons learned from the ASRG flight development project have been taken into consideration, the evaluation of the TDC design had not been completed for some existing environments or relatively new requirements. To further assess the TDC design, a series of tasks were initiated to evaluate degradation for units that have operated unattended for over 105,000 hours, demonstrate robustness to a random vibration environment, characterize and evaluate performance for varying lateral load profiles. The status for each task are described.

Wilson, Scott D.↗
NASA NTRS2018

Hardware Assessment in Support of the Dynamic Power Convertor Development Effort

Stirling Radioisotope Power Systems (RPS) are being developed by NASAs RPS Program in collaboration with the U.S. Department of Energy (DOE). Efforts ranging from 2001 to 2015 enabled development of the Technology Demonstration Convertor (TDC) for use in the 110-watt Stirling Radioisotope Generator (SRG-110) and the Advanced Stirling Convertor (ASC) for use in the Advanced Stirling Radioisotope Generator (ASRG). The DOE selected Lockheed Martin Space Systems Company (LMSSC) as the system integration contractor for both flight development efforts. The SRG-110 housed two TDCs fabricated by Infinia and resulted in the production of 16x demonstration units and 2x engineering units. The project was redirected in 2006 to make use of a more efficient and lower mass ASCs under development by Sunpower Inc. The DOE managed the flight contract with LMSSC and subcontractor Sunpower Inc. from 2007 to 2013 to build the ASRG, with support from NASA Glenn Research Center (GRC). Sunpower Inc. held two parallel contracts to produce ASCs, one with Lockheed Martin to produce ASC-F flight units and one with GRC for the production of ASC-E3 engineering unit pathfinders that were used to refine the flight design and production processes. The DOE initiated termination of the ASRG contract in late 2013. After ASRG had ended, GRC completed characterization testing of the ASRG Engineering Unit 2 (EU2) and the GRC contract with Sunpower was also completed. The NASA RPS Program Office has recently initiated a new Dynamic Power Conversion development effort which includes the potential maturation of Stirling, Brayton, and Rankine power convertors for the next generation of RPS. The effort started with the request for proposal and review of submits. Contracts are anticipated for release in 2017 and will initially focus on a design phase prior to fabrication and testing. This new effort will focus on robustness in addition to high efficiency, specific power, and reliability. Also, some requirements introduced during the ASRG contract have also been included in the new effort, such as constant lateral loading. Due to the focus on robustness and new requirements relative to the older TDC design, the Stirling Cycle Development Project has initiated an assessment of government owned hardware to help inform requirements evolution and evaluation of future designs. While lessons learned from the ASRG flight development project have been taken into consideration, the evaluation of the TDC design had not been completed for some existing environments or relatively new requirements. To further assess the TDC design, a series of tasks were initiated to evaluate degradation for units that have operated unattended for over 105,000 hours, demonstrate robustness to a random vibration environment, characterize and evaluate performance for varying lateral load profiles. The status for each task are described.

Wilson, Scott D.↗