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Prototype Demonstration of Solar Carbothermal System to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Aaron Paz

Pressurized-Cell Experiment

Pressurized-cell detectors were developed and constructed at the Langley Research Center to obtain a direct measurement of the micrometeoroid puncture hazard to thin structural material. A total of 160 detectors were mounted around the periphery of the rocket motor used on the Explorer XIII satellite. (See fig. IX-1.) Material thicknesses of 0.001, 0.0015, 0.002, 0.0025, and 0.005 inch were used on the detectors. The exposed surface of the test material of each detector was 21.8 square inches and the total exposed surface of the 160 detectors was 24.2 square feet. The average weight of the detectors was 68 grams.

Micrometeoroid

Swamp Works Regolith Compaction Technologies

While the level of compaction below the lunar surface increases quickly after only a few cm of depth, in many cases during a construction mission there will be a need to excavate and transport regolith to a new location for cut-and-fill or horizontal construction of structures such as berms. In these cases to achieve high levels of bulk density, compaction must be per-formed. Additionally, in some cases surface technologies such as systems that sinter/melt the surface may desire the maximum possible compaction at the sur-face to improve melting/heating performance and the final material strength properties. Kennedy Space Center’s (KSC) Swamp Works has developed two means of compaction, lunar and mar-tian compaction. Planetary Autonomous Compaction Technology (PACT) which is part of the Multifunction End Effector for Regolith Compaction Acquisition and Transfer (MEERCAT) robotic arm end effector system’s capabilities and the Site Preparation Tooling for Operations on Mobility Platforms (STOMP) vibratory roller compactor. PACT on MEERCAT has been demonstrated to a TRL 5 and STOMP to a TRL 4 in ambient testing. The results of PACT on MEERCAT and STOMP testing will be shared with results for various simulants including BP-1, ICN-LHT-1G (aka CSM-LHT-1G), RDW-LHT-1GH (a simulant developed for the Mason Tipping Point to match characteristics of ICN-LHT-1G), and Exolith LHS-1E. This will also include discussions on methods used to verify relative density before and after compaction and means to verify density effects below depth. To calculate relative density, maximum and minimum densities for simulants were taken from literature and additional lab testing (publication in work).

redwire

Terrestrial Environment (Climatic) Criteria Guidelines for Use in Aerospace Vehicle Development, 1973 Revision

This document provides guidelines on probable climatic extremes and probabilities-of-occurrence of terrestrial environment data specifically applicable for NASA space vehicles and associated equipment development. The geographic areas encompassed are The Eastern Test Range (Cape Kennedy, Florida); Huntsville, Alabama; New Orleans, Louisiana; The Space and Missile Test Center (Vandenberg AFB California); Sacramento, California; Wallops Test Range (Wallops Island, Virginia); White Sands Missile Range, New Mexico; and intermediate transportation areas. In addition, sections have been included to provide information on the general distribution of natural environment extremes in the United States (excluding Alaska and Hawaii), cloud cover, and some worldwide climatic extremes. Although all these areas are covered, the major emphasis is given to the Kennedy Space Center launch area and Vandenburg Air Force Base due to importance in NASA's future large space vehicle programs. This document presents the latest available information on probable climatic extremes, and supersedes information presented in TM X-64589. The information in this document is recommended for employment in the development of space vehicles and associated equipment design and operational criteria, unless otherwise stated in contract work specifications.

cloud cover

Atmospheric, Non-Combusting Droplet Sizing and Spray Imaging Results From a Non-Proprietary Aero Gas Turbine Engine Pressure Swirl Atomizer using Shadowgraphy and Planar Laser Scatter

Members from industry and federal agencies of the United States have developed a collaborating group focused on improving the understanding of the atomization processes common to gas turbine engines. The group is aimed on providing high quality data using x-ray diagnostics in the internal geometry and the near-field dense spray as well as optical diagnostics in the visible spectrum, downstream of the nozzle. This paper reports results from one of the two non-proprietary injectors designs from the group: the primary-secondary injector. In particular, we characterize the spray from only the primary, pressure-swirl atomizing circuit using water through the nozzle. We observed Sauter mean diameter decreased with increased water pressure drop across the nozzle. SMD was also collected at three axial distances and showed decreased size with distance from the nozzle. Planar laser sheet droplet scattering provided qualitative assessment of the spray. Higher water pressure drops provided better atomization than lower pressure drops. The addition of swirling air flow through the injector alleviates and improves the atomization quality, particularly at the lower water pressure drops.

optical diagnostics

Life cycle test results of a bipolar nickel hydrogen battery

A history is given of low Earth orbit (LEO) laboratory test data on a 6.5 ampere-hour bipolar nickel hydrogen battery designed and built at the NASA Lewis Research Center. The bipolar concept is a means of achieving the goal of producing an acceptable battery, of higher energy density, able to withstand the demands of low-Earth-orbit regimes. Over 4100 LEO cycles were established on a ten cell battery. It seems that any perturbation on normal cycling effects the cells performance. Explanations and theories of the battery's behavior are varied and widespread among those closely associated with it. Deep discharging does provide a reconditioning effect and further experimentation is planned in this area. The battery watt-hour efficiency is about 75 percent and the time averaged, discharge voltage is about 1.26 volts for all cells at both the C/4 and LEO rate. Since a significant portion of the electrode capacity has degraded, the LEO cycle discharges are approaching depths of 90 to 100 percent of the high rate capacity. Therefore, the low end-of-discharge voltages occur precipitously after the knee of the discharge curve and is more an indication of electrode capacity and is a lesser indicator of overall cell performance.

Cataldo, R. L.

SERENE: Saturn Enceladus Return Explorer with Nuclear Electric Propulsion

A ‘quick’ Enceladus sample return mission concept was developed based on the scientist recommendations at the recent ‘Accelerating Space Science with Nuclear Technology Workshop’. The Nuclear Electric Propulsion spacecraft assumed a follow-on 40 kWe nuclear reactor using the demonstrated 40 kWe Fission Surface Power system, expected in the early 2030s. The NEP vehicle also utilized a set of NEXT-C ion thrusters as well as planned Artemis commercial launchers. By launching the 40 kW NEP vehicle on a Starship and adding the propellants of 15 tankers, the 27t probe could be sent on a direct trajectory to Saturn (no Earth or Jupiter flybys) where NEP was used for Saturn capture, spiral down, spiral up and return to the Earth. A small lander obtained the surface Enceladus sample. Using the 40 kW NEP provided a round-trip time of only 16.5 years. A second option was more attractive from a science perspective whereby the NEP vehicle would deliver a large, 6t chemical lander to low Enceladus orbit where it would grab and return a sample to Earth (similar to the recent Orbilander design but in reverse). After deploying the lander, the NEP vehicle would stay in Saturn space performing a moon tour by orbiting four more moons and mapping the large moon of Titan. This option took slightly longer (18.5 yrs) due to the chemical return leg limitations. Both options demonstrated the agility, payload capability, and sample return goals the workshop recommended. An all-chemical option with two stages was roughly analyzed but took 21.5 yrs and required a Jupiter gravity assist.

Nuclear Electric Propulsion

Prototype Demonstration of an Integrated Solar Concentrator System and Carbothermal Reactor Using Solar Energy to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Oxygen from Regolith

Precipitation Hardenable High Temperature Shape Memory Alloy

A composition of the invention is a high temperature shape memory alloy having high work output, and is made from (Ni+Pt+Y) x Ti (100-x) wherein x is present in a total amount of 49-55 atomic % Pt is present in a total amount of 10-30 atomic %, Y is one or more of Au, Pd. and Cu and is present in a total amount of 0 to 10 atomic %. The alloy has a matrix phase wherein the total concentration of Ni, Pt, and the one or more of Pd. Au, and Cu is greater than 50 atomic %.

Ronald D Noebe

Risks of Depress as a Fire Suppression Technique in Spacecraft

Spacecraft are designed to prevent fires through careful material selection and configuration control combined with electrical design controls and isolation of ignition sources. Despite these best efforts, fire risk still exists due to the potential for configuration changes with the introduction of crew and the potential for a ‘failure of imagination’ by designers in anticipating all fuel and ignition sources. Therefore, fire suppression is a critical capability for any crewed spacecraft as a last resort for crew survival. Many spacecraft suppression methods have relied on fire suppressants such as compressed carbon dioxide, nitrogen, and water. A proposed alternative is depressurization of the cabin as a method to extinguish a fire. Limited testing was conducted during Skylab and showed that depress could result in stirring the air flow and aggravating a fire before extinguishing. However, limited information was available on how the test was conducted. To better characterize the approach, testing was conducted at NASA’s White Sands Test Facility to evaluate the effect of depressurization on material extinguishment. The results showed that depressurization does not provide a safe and effective fire suppression capability. The testing approach, results, and conclusions are described and discussed.

Toni Griego

Advances in Tactical Rocket Propulsion

An AGARD Colloquium on 'Progress in Tactical Rocket Propulsion' was held at La Jolla, California, on April 22 and 23, 1965. The unclassified papers, or unclassified versions of classified papers, presented at this meeting form the contents of the present AGARD conference proceedings, which has been identified by a new title that reflects more properly the scope of the remaining technical papers. The articles contained in this volume represent significant evaluations of the status of solid-propellant, liquid-propellant and hybrid-propellant rocket development. Together with the reviews, they should provide a useful reference source for research workers and students alike.

S S Penner

Manned Mars Systems Study

A study is underway to determine attractive system options, perform trade studies, and provide comparative data for astronaut missions to Mars. Because of an emphasis in this work on deriving requirements and candidates for the transportation and facility infrastructure for such missions, all relevant technologies and mission constraints are also being considered. These include on-orbit assembly, trajectory type, launch opportunities, propellant storage, crew size, cabin pressure, artificial gravity, life-support systems, radiation hazards, power/energy storage, thermal control, human factors, communications, abort scenarios, landing techniques, exploration strategies and science activities. It is planned to scope several example missions and to identify enabling and significantly enhancing technologies for accomplishing the goals of the human exploration of Mars.

Benton C Clark

Swamp Works Regolith Compaction Technologies

While the level of compaction below the lunar surface increases quickly after only a few cm of depth, in many cases during a construction mission there will be a need to excavate and transport regolith to a new location for cut-and-fill or horizontal construction of structures such as berms. In these cases to achieve high levels of bulk density, compaction must be per-formed. Additionally, in some cases surface technolo-gies such as systems that sinter/melt the surface may desire the maximum possible compaction at the sur-face to improve melting/heating performance and the final material strength properties. Kennedy Space Center’s (KSC) Swamp Works has developed two means of compaction, lunar and mar-tian compaction. Planetary Autonomous Compaction Technology (PACT) which is part of the Multifunction End Effector for Regolith Compaction Acquisition and Transfer (MEERCAT [1]) robotic arm end effector system’s capabilities and the Site Preparation Tooling for Operations on Mobility Platforms (STOMP [2]) vibratory roller compactor. PACT on MEERCAT has been demonstrated to a TRL 5 and STOMP to a TRL 4 in ambient testing. The results of PACT on MEERCAT and STOMP testing will be shared with results for various simulants including BP-1, ICN-LHT-1G (aka CSM-LHT-1G), RDW-LHT-1GH (a simulant developed for the Mason Tipping Point to match characteristics of ICN-LHT-1G), and Exolith LHS-1E. This will also include discus-sions on methods used to verify relative density before and after compaction and means to verify density effects below depth. To calculate relative density, maximum and minimum densities for simulants were taken from literature [3] [4] [5] and additional lab test-ing (publication in work).

vibration

Enabling Reliable, Fault-Tolerant Autonomous Lunar Habitats with High-Performance Spaceflight Computing

The lunar surface presents unfavorable constraints and harsh living conditions. To address these challenges, autonomous habitats will require complex integrated systems that combine advanced software, high-performance hardware, and cutting-edge sensors to ensure sustainability, safety, and operational efficiency. Consequently, maintaining a sustainable presence on the Moon requires reliable infrastructure and efficient development, precise monitoring, and utilization of resources within a lunar installation. These elements are essential not only to ensure that lunar settlement can be long-term, self-sustaining, and resource-efficient, but also to serve as a foundation for future missions and eventual human habitation on Mars. Humans are not native to the Moon; therefore, our survival and ability to thrive will depend on autonomous systems that can foster safety and resilience through high-availability architectures, graceful degradation, and highly fault-tolerant spaceflight hardware capable of continuing operation during failures. This requires advanced human-rated distributed systems architectures with specialized electronics, scalable capabilities, and an integrated design approach. Unlike current practices focused on short-term missions and regularly maintained components, permanent lunar compute systems must be designed for extended operations beyond mission durations. This paper explores the necessity of transitioning toward fault- tolerant, highly autonomous hardware systems designed for multi-year missions. It also identifies critical subsystems that require high levels of autonomy, supported by radiation-hardened processors and extreme thermal loads, which are essential to mitigate long-term degradation and ensure sustainable lunar habitation. Finally, the paper aligns with NASA’s identified Civil Space Shortfalls, particularly in high-performance onboard computing, advanced data acquisition, extreme-environment avionics, radiation monitoring and countermeasures, and autonomous health management. It proposes NASA’s new High-Performance Spaceflight Computing (HPSC) processor as a turnkey solution, delivering 100 times the performance-per-watt of legacy rad-hard CPUs and enabling onboard AI, edge computing, and fault-tolerant features essential for sustained lunar autonomy and beyond.

Sarkis S Mikaelian

Thermal expansion behavior of LDEF metal matrix composites

The effects of the space environment on the thermal expansion stability of metal matrix composites (graphite/Al and graphite/Mg) will be presented. A sample from each category of metal matrix composites mounted on the leading and trailing edge was chosen for analysis of the temperature-time-thermal strain histories. Typical thermal expansion curves over the same range of temperature were selected at the beginning, mid, and end of the recording duration. The thermal expansion of selected post-flight LDEF samples were measured over the same range of temperature in the laboratory using a Michelson laser interferometer. The thermal strains were monitored concurrently with a laser interferometer and a mounted strain gage.

T. D. Le

Bosch Carbon Catalyst Regeneration in Water III: Experiments for and Related to Thermal Shock

Bosch technology has the potential to close the atmospheric revitalization loop by providing theoretically 100% regeneration of metabolic carbon dioxide into oxygen. The main obstacle to using Bosch technology is over-pressurization issues in the carbon formation reactor. Prior work on Bosch catalyst regeneration established that agitating carbon coated beads in water broke up pressure causing clogs and regenerated the catalyst surface. This process proved to be time consuming with experiments taking at least one hour to regenerate ten grams of carbon coated beads. In an attempt to shorten the processing time, thermally shocking the carbon coated beads prior to mechanical agitation was tested. Agitating the carbon coated beads after exposure to a saturated steam environment was also tested to ensure that the steam generated by thermally shocking the carbon coated beads would not cause adverse effects. The rationale behind thermally shocking the carbon coated beads is that the bead would pull away from the carbon shell due to a difference in the thermal expansion coefficients. The results of this project show that the processing time can be cut in half when compared to previous work, and that saturated steam has little to no effect on regeneration.

Bosch Process

Fuel injector design for high temperature aircraft engine

The objective of the Innovative High Temperature Aircraft Engine Fuel Nozzle Program was to design and evaluate a nozzle capable of operating at a combustor inlet air temperature of 1600 F (1144 K) and a fuel temperature of 350 F (450 K). The nozzle was designed to meet the same performance requirements and fit within the size envelope of a current production dual orifice fuel nozzle. The design approach was to use improved thermal protection and fuel passage geometry in combination with fuel passage surface treatment to minimize coking at these extreme fuel and air temperatures. Heat transfer models of several fuel injector concepts were used to optimize the thermal protection, while sample tube coking tests were run to evaluate the effect of surface finish, coatings and tube material on the coking rate. Based on heat transfer analysis, additional air gaps, reduced fuel passage flow area and use of ceramic tip components reduced local fuel wetted wall temperatures by more than 200 F (100 K) when compared to a current production fuel nozzle. Sample tube coking test results showed the importance of surface finish on the fuel coking rate. Therefore, a one micro-inch (0.025 micron) roughness was specified for all fuel passage surfaces. A novel flow divider valve in the tip was also employed to reduce weight, allow room for additional thermal protection, and provide back pressure to reduce the risk of fuel vaporization. The fuel nozzle was fabricated and evaluated in a series of high temperature coking tests. Initial results of these tests indicate that thermal protection and surface treatments were partially successful in preventing nozzle fouling, but additional refinement of the internal flowpath is needed to prevent buildup of coke particles that partially blocked the spin slots which meter the nozzle fuel flow.

R. W. Stickles