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NASA NTRS2016

James Webb Space Telescope Integrated Science Instrument Module Thermal Vacuum Thermal Balance Test Campaign at NASA's Goddard Space Flight Center

The James Webb Space Telescope is a large infrared telescope with a 6.5-meter primary mirror, designed as a successor to the Hubble Space Telescope when launched in 2018. Three of the four science instruments contained within the Integrated Science Instrument Module (ISIM) are passively cooled to their operational temperature range of 36K to 40K with radiators, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the ISIM element level has taken place in three separate highly challenging and extremely complex thermal tests within a gaseous helium-cooled shroud inside Goddard Space Flight Centers Space Environment Simulator. Special data acquisition software was developed for these tests to monitor over 1700 flight and test sensor measurements, track over 50 gradients, component rates, and temperature limits in real time against defined constraints and limitations, and guide the complex transition from ambient to final cryogenic temperatures and back. This extremely flexible system has proven highly successful in safeguarding the nearly $2B science payload during the 3.5-month-long thermal tests. Heat flow measurement instrumentation, or Q-meters, were also specially developed for these tests. These devices provide thermal boundaries o the flight hardware while measuring instrument heat loads up to 600 mW with an estimated uncertainty of 2 mW in test, enabling accurate thermal model correlation, hardware design validation, and workmanship verification. The high accuracy heat load measurements provided first evidence of a potentially serious hardware design issue that was subsequently corrected. This paper provides an overview of the ISIM-level thermal-vacuum tests and thermal objectives; explains the thermal test configuration and thermal balances; describes special measurement instrumentation and monitoring and control software; presents key test thermal results; lists problems encountered during testing and lessons learned.

JWST ISIM Thermal↗

DOE OSTI2025

Improving the Capabilities and Computational Efficiency of the RTE+RRTMGP Radiation Code (Final Report)

This report details progress on the RTE+RRTMGP radiation codes made during the period of performance. RTE+RRTMGP is a set of codes for computing radiative fluxes in planetary atmospheres. RRTMGP uses a k-distribution to provide an optical description (absorption and possibly Rayleigh optical depth) of the gaseous atmosphere, along with the relevant source functions, on a pre-determined spectral grid given temperatures, pressures, and gas concentration. RTE computes fluxes given spectrally-resolved optical descriptions and source functions. Spectrally-resolved fluxes are summarized (“reduced”) via a user extensible class. The initial release of the code and the design choices are described in Pincus et al. 2019; the codes are available on Github. Although RRTMGP was based on current (at the time) empirical spectroscopic data, RTE and RRTMGP were developed in large part to modernize software practices. The design focused on flexibility broadly interpreted: by separating code from data and allowing data to drive computation; in coupling to the host model (e.g. the coupling of clouds to radiative fluxes is user-controlled); with respect to programming languages (computational tasks are accessed via widely-compatible C interfaces); and with respect to hardware (the codes run on a range of CPU and GPU architectures). The code also puts an emphasis on modularity and clarity. RTE+RRTMGP v1.0 was released in September 20219. This award supported the evolution of the RTE+RRTMGP code base to support greater flexibility, accuracy, and efficiency.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRSDate not supplied

Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures

NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.

Additive Manufacturing↗

NASA NTRS2005

Lessons From the Pioneer Venus Program

We began the Pioneer Venus contract in late 1974 with a planned launch of the Orbiter in May 1978 and the Multiprobe in August 1978. Because we had four years, we thought there was plenty of time. As it turned out, we barely made the launch dates. The Orbiter was relatively straightforward, compared to the Multiprobe Bus and Probes that had to survive descent through the harsh Venusian atmosphere. To help overcome our many Multiprobe problems we formed a strong global team. The GE reentry team in Philadelphia, experienced in designing vehicles to enter the earth s atmosphere, was assigned the responsibility for the Probe entry system, including protective heat shielding and parachute design to extract the scienceladen Large Probe pressure vessel and control its descent through the Venusian clouds. Since the Probes had to remain stable as they descended through the Venus atmosphere, we used the aerodynamic expertise at the Hughes Missile Division, NASA s Ames Research Center and the Langley Research Center. Since the pressure at the surface of Venus was equivalent to an ocean depth of 3300 feet, we went to the Navy s David Taylor Research Center for their deepsea expertise. To test the pressure vessel at the high pressure and temperatures anticipated at Venus we went to the only facility capable of simulating the Venus surface environment, the Southwest Research Institute in San Antonio, Texas. We had dozens of subcontractors all over the world. As we developed our design, we began an extensive program to validate the ability of our Probe hardware to withstand the Venus environment. During this testing, we encountered numerous problems, mostly associated with adapting earth-based hardware to operate in the anticipated Venus environment. For example, the Large Probe pressure vessel imploded with a very loud bang the first time we tested its ability to withstand the high pressure and temperature on the Venusian surface. We had to go back and redesign, increasing the pressure vessel wall thickness. In addition, during the first tests of the parachute system, our parachute system ripped apart and had to be redesigned. Finally, at the aptly named test range in Truth or Consequences, New Mexico, we successfully demonstrated the parachute design by drop

Dorfman, Steven D.↗

NASA NTRS2014

Gaseous Non-Premixed Flame Research Planned for the International Space Station

Thus far, studies of gaseous diffusion flames on the International Space Station (ISS) have been limited to research conducted in the Microgravity Science Glovebox (MSG) in mid-2009 and early 2012. The research was performed with limited instrumentation, but novel techniques allowed for the determination of the soot temperature and volume fraction. Development is now underway for the next experiments of this type. The Advanced Combustion via Microgravity Experiments (ACME) project consists of five independent experiments that will be conducted with expanded instrumentation within the stations Combustion Integrated Rack (CIR). ACMEs goals are to improve our understanding of flame stability and extinction limits, soot control and reduction, oxygen-enriched combustion which could enable practical carbon sequestration, combustion at fuel lean conditions where both optimum performance and low emissions can be achieved, the use of electric fields for combustion control, and materials flammability. The microgravity environment provides longer residence times and larger length scales, yielding a broad range of flame conditions which are beneficial for simplified analysis, e.g., of limit behaviour where chemical kinetics are important. The detailed design of the modular ACME hardware, e.g., with exchangeable burners, is nearing completion, and it is expected that on-orbit testing will begin in 2016.

microgravity↗

NASA NTRSDate not supplied

EVA Swab Kit: Tools and Techniques for Collecting Aseptic Samples from Crewed Space Missions

Introduction: When we send humans to search for life on other planets, we'll need to know what we brought with us versus what may already be there. To ensure our crewed spacecraft meet planetary protection requirements—and to protect our science from human contamination—we'll need to assess and verify whether micro-organisms may be leaking/venting from our spacesuits. This requires collecting samples under Extravehicular Activity (EVA) conditions. Detailed, systematic research on forward contamination from robotic spacecraft has been steadily progressing since the Viking missions, but systematic studies of contamination from space suits has not been conducted in many years. The modern EMU (Extravehicular Mobility Unit) suit used by NASA is designed to leak at rates as high as 100 cc/min. Before humans land on Mars there is a critical need to understand the types and quantities of microbes that could be introduced via space suits. The Human Forward Contamination Assessment team at NASA’s Johnson Space Center (JSC) has developed a prototype EVA swab tool [1,2,3,4] designed for use in space to sample cleaned and uncleaned space suits to determine the present day microbial load and eventually the rate of leakage. The ability to assess microbial leakage early in advanced space suit and life support system design cycles will help avoid costly hardware redesign later. Test Objectives: The primary objective of EMU testing was to characterize the type of micro-organisms typically found on or near selected suit pressure joints under suit differential pressure conditions. Most human-borne microbes can fit through a 0.5 to 1.0 µm gap. Knowing which joints are more likely to leak will inform hardware design decisions. Knowing which types of micro-organisms may leak from EVA suits provides a basis for subsequent studies to characterize the viability of those organisms under destination conditions, as well as how far they might spread through natural or human-influenced processes. That data, in turn, will inform exploration mission operations and hardware design. The secondary objective of testing was to evaluate the interface between a fully suited test subject and the EVA swab tool at vacuum. Bulky EVA suits can restrict movement and limit visibility through the helmet visor. Fully suited testing is important for identifying tool design issues prior to flight. At exploration destinations, such as Mars, suited crew may be required to periodically sample their suits as part of an environmental monitoring protocol. Suit Microbial Sampling Results: This report details results of microbial swabs collected from current flight suit configurations worn by crew members assigned to upcoming ISS expedition missions as well as swabs collected from prototype suits intended for use on the Orion spacecraft. These tests were intended to characterize the types of contaminants found on flight suits under current, typical handling conditions. No attempt was made to change suit handling procedures, provide additional sterilization, or to limit typical potential contaminant sources. Using culture based techniques, we cultivated 235 CFU (colony forming units) comprised of 26 bacterial species and one fungal species on the outside of the suits. The fungal species and 14 of the bacterial species were unique to the suit surfaces and were not detected in any of the background samples collected within the chambers. We sequenced 755,434 ribosomal fragments on all of the suit surfaces from swab samples. 557,016 of these sequences represent DNA that survived at least 4 hours at vacuum. These sequences formed 2,464 OTU's (Operational Taxonomic Units, 97% similarity) showing low diversity in the samples. The most abundant sequences that survived vacuum belong to the genera Staphyloccocus, Ralstona, Bacillus and Rhodobacter all of which are common to the human microbiome. [5] See Danko et al., (2021) for more complete details of these first analyses. Further analysis of EVA suit materials with respect to the efficacy of various cleaning protocols and engineered containment solutions is planned to inform suit design for NASA’s Artemis Moon to Mars program crew testing. Swab Tool Function Results: The kit was demonstrated for fit and function in suited subject vacuum tests to determine how well the tool worked as an aseptic microbial sampling device as well as to identify any design elements that could be upgraded for EVA task specific improvement. It was found that sample acquisition efficacy could be enhanced by redesign of the sample canister to end-effector interface. Several modifications of the sample caddy assemblies to optimize EVA safety and functionality were also identified. Consequently, fabrication of the redesigned sample canister to end-effector assembly interfaces and and the sample caddy assemblies are required. Fabrication of sixteen flight sample canister assemblies (8 per each of two EVA Swab Kits) and two sample caddy assemblies are in process to be followed by hardware testing and certification to produce two flight-certified EVA Swab Kits for transport to ISS no earlier than summer of 2022. Sampling Strategy: The International Space Station is an ideal testbed for systematic studies of contamination from crewed vehicles since it has been continuously occupied for 20 years and exposed to non-terrestrial conditions. We will sample the exterior of the ISS during EVA using a purpose-built swab tool capable of maintaining sterility while undergoing temperature changes from -151 to +121°C under hard vacuum. Prior to each EVA, the project team will work with ISS mission managers to identify precise sampling locations, which will vary by EVA based on the translation paths and worksites scheduled for that particular EVA. Ideally, translation path handrails and areas near ECLSS (Environmental Control and Life Support System) external vent openings on a spacecraft would be assessed. There are currently more than a dozen ECLSS external vents on the ISS. Some are connected to systems that vent waste products, while others are intended to equalize cabin pressure. As EVA opportunity allows, microbial samples from any of these external vents would provide a valuable data point, though some will be more useful than others. Four criteria have been identified to help prioritize sampling sites near vents: • EVA Accessibility: To minimize cost, it is desired to piggy-back onto a planned EVA. Therefore, the sampling location must be readily accessible by an EVA crew • Type of Vented Products: Vent products that have been in direct contact with crew, such as cabin air, are more likely to contain microorganisms than vent products associated with isolated systems, such as experiment module combustion products. • Mass of Vented Products: Higher-flow vents are more likely to contain detectible levels of microbial contaminants than lower-flow vents. • Local Environment: Sample locations with relatively benign local conditions, such as warm surfaces shielded from direct ultraviolet (UV) radiation exposure, may be more likely to support microbial growth than locations with harsher local environmental conditions. Because EVA accessibility is the most important criteria, the proposal team worked with an astronaut and flight controllers using the Dynamic Onboard Ubiquitous Graphics (DOUG) tool. The DOUG virtual environment allows an operator to “fly” around the current ISS vehicle configuration to assess EVA translation paths, attach points, and keep-out zones. While analysis on station or rapid return to Earth would be preferable, samples collected from the exterior of the ISS have already been exposed to temperature variations between -157 and +121 °C as well as hard vacuum. Therefore, they should be fairly stable and robust. We hypothesize that samples collected from the ISS exterior could be stored for up to 6 months at -80°C without degradation. Sample canisters will be returned to Earth while frozen at -80°C for analysis, and sterilized canisters can be re-flown back to ISS to support additional sampling opportunities Relevance to NASA Exploration Objectives: These data will allow us to identify new or improved methods, technologies, and procedures for spacecraft sterilization and leakage mitigation to minimize the amount of contamination introduced to the environment by human explorers. This work is funded by NASA research grant: NNH18ZDA001N-PPR References: [1] Bell, M.S. et al. (2015) LPS XLVI, Abst. #1832 [2] Rucker et al. (2018) 42nd COSPAR (PPP.3) [3] Bell, M.S. et al. (2019) Mars Extant Life Conference, Abst. #5096.[4] Bell, M.S. et al., (2020) 43rd COSPAR (BO.2).[5] Danko D, et.al.,(2021)Front.Microbiol.12:608478.

Mary Suzanne Bell↗

NASA NTRS2003

Initial closed operation of the CELSS Test Facility Engineering Development Unit

As part of the NASA Advanced Life Support Flight Program, a Controlled Ecological Life Support System (CELSS) Test Facility Engineering Development Unit has been constructed and is undergoing initial operational testing at NASA Ames Research Center. The Engineering Development Unit (EDU) is a tightly closed, stringently controlled, ground-based testbed which provides a broad range of environmental conditions under which a variety of CELSS higher plant crops can be grown. Although the EDU was developed primarily to provide near-term engineering data and a realistic determination of the subsystem and system requirements necessary for the fabrication of a comparable flight unit, the EDU has also provided a means to evaluate plant crop productivity and physiology under controlled conditions. This paper describes the initial closed operational testing of the EDU, with emphasis on the hardware performance capabilities. Measured performance data during a 28-day closed operation period are compared with the specified functional requirements, and an example of inferring crop growth parameters from the test data is presented. Plans for future science and technology testing are also discussed. Published by Elsevier Science Ltd on behalf of COSPAR.

Lettuce/growth & development/metabolism↗

DOE OSTI2020

Completion Effects on Diagnosing Multistage Facture Treatments with Distributed Temperature Sensing

Summary Distributed temperature sensing (DTS) is a valuable tool to diagnose multistage hydraulic fracture treatments. When a stage interval is shut in, the clusters that take more fluid during pumping warm up more slowly. Therefore, the fluid volume injected into each cluster can be quantitatively interpreted by numerical inversion of the warm-back temperature behavior. This general concept assumes that the different warm-back behavior is controlled by only the injected fluid volume; however, recent observations of DTS data indicate that completion configurations significantly influence the warm-back behavior. This paper investigates the completion effects on the DTS interpretation. In ideal conditions, when a stage is fractured, the upstream stage intervals should show an almost uniform temperature that is close to the injected fluid temperature. This is due to the high fluid velocity of injected fluid in the wellbore, and the upstream intervals have not been perforated (noncommunicating intervals), so the only heat transfer is heat conduction between the wellbore fluid and the surrounding reservoir. But the field DTS data show considerably irregular variations in temperature along the upstream stage intervals. These variations are caused by the completion effects. The nonuniform temperature profile is caused by different heat transfer behavior induced by completion hardware along the production casing string, such as joints, clamps, and blast protectors, and by the sensing cable location in the cement, as well as the cement quality. Because the varying heat transfer behavior impacts the warm-back behavior as well as the temperature profile, the completion effects need to be considered in DTS interpretation. A method of DTS interpretation considering the completion effects to diagnose multistage fracture treatments was developed. Because the heat transfer between a wellbore and a reservoir depends on the overall heat transfer coefficient describing heat conduction through the completion in a forward model, this parameter needs to be tuned all along the wellbore. To calibrate the completion effect, the temperature inversion is conducted using the temperature measured at a stage interval that is upstream of a stage interval currently being treated. Because the interpreted stage interval is not perforated at that time, the thermal behavior at the noncommunicating interval is governed by only the heat conduction through the completion environment. Once the effective values of the overall heat transfer coefficient are estimated along the interpreted stage interval, they can be assumed to be constant physical parameters. Then, the fluid volume distribution is interpreted by using the effective overall heat transfer coefficient profile along each interval. This study provides a field application of the developed interpretation method. The new interpretation method provides more accurate diagnosis of fracture treatments by DTS interpretation.

Engineering↗

DOE OSTI2025

Optimizing Hydronic Heating for Comfort and Performance in Multifamily Housing

Inefficient control settings in multifamily boilers often lead to substantial energy and cost penalties. To address this, a Fault Detection and Diagnostic (FDD) tool was developed to automate data analysis and identify operational faults such as suboptimal outdoor temperature sensor placement, misconfigured outdoor air reset (OAR) curves, excess boiler cycling, and domestic hot water (DHW) setpoint errors. By comparing pre- and post-implementation periods and applying engineering models, the tool quantifies energy savings and reduces manual analysis time by over 90%. Testing on over 100 monitored sites and a targeted subset of 12 buildings showed an average 11% energy savings from remote optimization; further validation across 19 OAR curve changes confirmed the tool’s accuracy, predicting actual savings within ±5% for most cases. Simple payback can be under three years for many multifamily buildings, though rising hardware, labor, and fuel costs create uncertainties, and decarbonization goals increasingly shift focus to electrification. The FDD tool remains invaluable for optimizing existing boilers, enhancing future electrification measures, and adapting to new technologies by refining building load estimates. In doing so, it supports both near-term efficiency and long-term transitions to low-carbon alternatives, ensuring buildings achieve substantial cost and energy benefits throughout their system lifecycles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1994

Optimization of moisture content for wheat seedling germination in a cellulose acetate medium for a space flight experiment

The Porous Tube Plant Nutrient Delivery System (PTPNDS), a hydrophilic, microporous ceramic tube hydroponic system designed for microgravity, will be tested in a middeck locker of the Space Shuttle. The flight experiment will focus on hardware operation and assess its ability to support seed germination and early seedling growth in microgravity. The water controlling system of the PTPNDS hardware has been successfully tested during the parabolic flight of the KC-135. One challenge to the development of the spaceflight experiment was to devise a method of holding seeds to the cylindrical porous tube. The seed holder must provide water and air to the seed, absorb water from the porous tube, withstand sterilization, provide a clear path for shoots and roots to emerge, and be composed of flight qualified materials. In preparation for the flight experiment, a wheat seed-holder has been designed that utilizes a cellulose acetate plug to facilitate imbibition and to hold the wheat seeds in contact with the porous tube in the correct orientation during the vibration of launch and the microgravity environment of orbit. Germination and growth studies with wheat at a range of temperatures showed that optimal moisture was 78% (by weight) in the cellulose acetate seed holders. These and other design considerations are discussed.

Johnson, Corinne F.↗

NASA NTRSDate not supplied

Design of a GRCop-42 Regeneratively Cooled Thrust Chamber Assembly and Feed System

An additively manufactured thrust chamber assembly was designed and printed using laser powder bed fusion. The NASA-developed material GRCop-42 was used for its high strength and high temperature characteristics. The combustion chamber and nozzle utilize regenerative coolant channels to achieve long duration hot fire tests. Design for additive manufacturing was used to create geometries not easily attainable with traditional machining. The thrust chamber assembly was post processed to ensure print quality and verify for testing. A feed system – encompassing all propellant lines, valves, sensors, and tanks – was designed and built to enable steady state, pressure regulated testing. Pressure transducers, thermocouples, and load cells were placed to enable measurements of the propellant properties and engine performance. Venturis and orifices were used throughout the system to control the flow rates to the thrust chamber. Aside from providing propellants, the feed system provides pressure using nitrogen, and purges the lines during shutdown. The design process for this testing platform is described. A testing campaign on the hardware will be conducted by the Akronauts Rocket Design Team at the University of Akron in Spring 2023.

Dillon M. Petty↗

NASA NTRSDate not supplied

Design of a GRCop-42 Regeneratively Cooled Thrust Chamber Assembly and Feed System

Dillon M. Petty↗

DOE OSTI2022

An optoelectronic heterostructure for neuromorphic computing: CdS/V 3 O 5

Nonvolatile resistive switching is one of the key phenomena for emerging applications in optoelectronics and neuromorphic computing. In most of the cases, an electric field is applied to a two terminal dielectric material device and leads to the formation of a low resistance filament due to ion migration. However, the stochastic nature of the ion migration can be an impediment for the device robustness and controllability, with uncontrolled variations of high and low resistance states or threshold voltages. Here, we report an optically induced resistive switching based on a CdS/V 3 O 5 heterostructure which can overcome this issue. V 3 O 5 is known to have a second order insulator to metal transition around T c ≈ 415 K, with an electrically induced threshold switching at room temperature. Upon illumination, the direct transfer of the photoinduced carriers from the CdS into V 3 O 5 produces a nonvolatile resistive switching at room temperature. The initial high resistance can be recovered by reaching the high temperature metallic phase, i.e., temperatures above T c . Interestingly, this resistive switching becomes volatile around the T c . In conclusion, by locally manipulating the volatile and nonvolatile resistive switching using electric field and light, this system is a promising platform for hardware based neuromorphic computing implementations.

97 MATHEMATICS AND COMPUTING↗

NASA NTRSDate not supplied

Hydrogen Peroxide-Water-Ethanol-Monopropellant Blend for CubeSat Propulsion

Monopropellant propulsion that provides high performance and low hazards compared to state-of-art hydrazine are being investigated under NASA, DOD and commercially sponsored green propellant research and development programs. This NASAeffort looks at phosphate stabilized 50% hydrogen peroxide/water –ethanol blends to evaluate their stability and combustion behavior in submillimeter diameter microtube combustion apparatus for cubesat propulsion applications. Exploratory 7-day stabilitytests find no pressure rise in a sealed test tube environment at room temperature indicating at least short term stability of the mixture. Temperature rise during combustion testing in resistively heated nickel microtube apparatus shows that micro-combustion is achieved in the tube. Propellant density is approximately 1.2 g/cm3compared to 1.0 g/cm3for hydrazine. Theoretical specific impulse of the stoichiometric blend is 219 s at a chamber pressure of 20 psia and an area ratio of 30:1. Density-specific impulseof this blendis263 swhile hydrazine is only about 215-220 sin small reaction control system thrusters. This provides about 20-22% more density-specific impulse for the cubesat compared to hydrazine. The theoreticalcombustion temperature is2168°F, whichis thermally compatible with stainless steel materials of constructionand the nickel catalystused in the tests. Combustion test results are given for stoichiometric, as well as fuel-leanand fuel-richpropellant formulations. Thesetests focus on thermally and catalytically supported combustionin the microtube, whichrequires a microtube preheat temperature of about 900°F and sufficient residence time to achieve combustion that is stable and anchored in the tubewithout blowing through the tube unreacted. Thrust class is expected to be in the 10 mN range based on flow rate and estimated specific impulse.Power requirements are generally below 25 Wto heat the tube. Steady state combustion testing is typically conducted for 3 minutes and shows littledegradation of the hardware over multiple test cyclesindicating thatthere is little catalyst degradation over time and littlecatalyst deactivation due tothe phosphate stabilizer inthe hydrogen peroxide.

Monopropellant↗

NASA NTRSDate not supplied

Use of Mechanical Heat Switch to Speed up TVAC Transitions on Flight Hardware Below 200K

Spaceflight hardware that operates at temperatures well below room temperature usually require being well isolated from their warmer environment in order to manage thermal parasitics adequately. This is especially true for spaceflight systems that rely on passive cooling such as a radiator. During ground testing, this design configuration can be problematic for TVAC cycling between operational temperature extremes, since the hardware temperatures may move extremely slowly and lengthen the duration of an already expensive and heavily staffed system-level TVAC campaign. One of the challenges of using an external means of speeding up temperature transitions is that a TVAC campaign usually also requires the simulation of flight-like environments to validate the design, and introducing a test feature to speed up transitions can disrupt the system such that flight-like environments are not achievable. Such an approach was used for the L’Ralph instrument level TVAC test. L’Ralph is a passively cooled instrument on the Lucy mission with planned flyby’s of the Trojan asteroids around 5.5 AU. The optics and visible detector are cooled below 190K, and the IR detector is cooled below 110K. During instrument TVAC qualification testing, a mechanical motor-controlled heat switch uses clamping pressure via a vise-grip mechanism to achieve faster temperature transitions by increasing the conduction to a cold sink. The heat switch system then disengages and employs zero-Q controls to achieve flight-like thermal environments for thermal balance plateaus. Results from stand-alone testing of the heat switch are discussed, including correlated on/off ratios and the expected conductance across its operational temperature range. Test data from an instrument level TVAC that successfully utilized the heat switch are also shown.

Daniel G Bae↗

NASA NTRS2002

The Design of a Remotely Operated Shutter (ROS) for Thermal Vacuum Testing

Space-flight hardware is required to meet specific outgassing criteria under vacuum conditions in order to reduce the risk of contaminating sensitive optics and spacecraft components. Under certain circumstances, it is desirable to measure the contamination levels that are being released from all surfaces of the test payload. This certification is often accomplished with a Total Outgassing Measurement (TOM) box. The TOM box has one 103.2 square centimeter (16 square inch) opening and one 4.84 square centimeter (0.75 square inches) opening. The larger opening allows contaminants to easily escape the box during the hardware bakeout phase. The smaller opening provides a limited conductance path for outgassed contaminants during the certification phase. A Thermoelectric Quartz Crystal Microbalance (TQCM) monitors the contamination levels inside the box to provide the total outgassing measurement. During transition from the bakeout phase to the certification phase, the TOM box is reconfigured to close the larger opening. For previous certifications, the vacuum chamber was returned to ambient conditions and the larger conductance port was closed manually. The ROS system eliminates the need to enter the chamber by remotely closing the large TOM box opening. Substantial schedule and cost savings are achieved through the use of this system. The ROS system consists of three main components; a shutter, a motion actuator, and an actuator controller. Each of these components was selected or designed to operate in an extreme-temperature and vacuum environment while providing a high level of reliability. Different types of motion actuators were considered for driving the shutter. Design parameters for the actuator included material properties, force capability, reliability, and cost.

Hale, Kathleen L.↗

NASA NTRS2009

NASA's Evolutionary Xenon Thruster (NEXT) Component Verification Testing

Component testing is a critical facet of the comprehensive thruster life validation strategy devised by the NASA s Evolutionary Xenon Thruster (NEXT) program. Component testing to-date has consisted of long-duration high voltage propellant isolator and high-cycle heater life validation testing. The high voltage propellant isolator, a heritage design, will be operated under different environmental condition in the NEXT ion thruster requiring verification testing. The life test of two NEXT isolators was initiated with comparable voltage and pressure conditions with a higher temperature than measured for the NEXT prototype-model thruster. To date the NEXT isolators have accumulated 18,300 h of operation. Measurements indicate a negligible increase in leakage current over the testing duration to date. NEXT 1/2 in. heaters, whose manufacturing and control processes have heritage, were selected for verification testing based upon the change in physical dimensions resulting in a higher operating voltage as well as potential differences in thermal environment. The heater fabrication processes, developed for the International Space Station (ISS) plasma contactor hollow cathode assembly, were utilized with modification of heater dimensions to accommodate a larger cathode. Cyclic testing of five 1/22 in. diameter heaters was initiated to validate these modified fabrication processes while retaining high reliability heaters. To date two of the heaters have been cycled to 10,000 cycles and suspended to preserve hardware. Three of the heaters have been cycled to failure giving a B10 life of 12,615 cycles, approximately 6,000 more cycles than the established qualification B10 life of the ISS plasma contactor heaters.

Herman, Daniel A.↗

NASA NTRS2012

Heat Melt Compaction as an Effective Treatment for Eliminating Microorganisms from Solid Waste

One of the technologies being tested at Ames Research Center as part of the logistics and repurposing project is heat melt compaction (HMC) of solid waste to reduce volume, remove water and render a biologically stable and safe product. Studies at Kennedy Space Center have focused on the efficacy of the heat melt compaction process for killing microorganisms in waste and specific compacter operation protocols, i.e., time and temperature, required to achieve a sterile, stable product. The work reported here includes a controlled study to examine the survival and potential re-growth of specific microorganisms over a 6-month period of storage after heating and compaction. Before heating and compaction, ersatz solid wastes were inoculated with Bacillus amyloliquefaciens and Rhodotorula mucilaginosa, previously isolated from recovered space shuttle mission food and packaging waste. Compacted HMC tiles were sampled for microbiological analysis at time points between 0 and 180 days of storage in a controlled environment chamber. In addition, biological indicator strips containing spores of Bacillus atrophaeus and Ceo bacillus stearothermophilus were imbedded in trash to assess the efficacy of the HMC process to achieve sterilization. Analysis of several tiles compacted at 180 C for times of 40 minutes to over 2 hours detected organisms in all tile samples with the exception of one exposed to 180 C for approximately 2 hours. Neither of the inoculated organisms was recovered, and the biological indicator strips were negative for growth in all tiles indicating at least local sterilization of tile areas. The findings suggest that minimum time/temperature combination is required for complete sterilization. Microbial analysis of tiles processed at lower temperatures from 130 C-150 C at varying times will be discussed, as well as analysis of the bacteria and fungi present on the compactor hardware as a result of exposure to the waste and the surrounding environment. The two organisms inoculated into the waste were among those isolated and identified from the HMC surfaces indicating the possibility of cross contamination.

Hummerick, Mary P.↗