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NASA NTRS2018

Dynamic Power Convertor Development for Radioisotope Power Systems at NASA Glenn Research Center

The Thermal Energy Conversion Branch at NASA Glenn Research Center is supporting the development of high-efficiency power convertors for use in radioisotope power systems (RPS). Significant progress was made toward such a system that utilized Stirling conversion during the 2001 to 2015 timeframe. Flight development of the Advanced Stirling Radioisotope Generator (ASRG) was canceled in 2013 by the U.S. Department of Energy (DOE) and NASA Headquarters primarily due to budget constraints, and the Advanced Stirling Convertor (ASC) technology contract was subsequently concluded in 2015. A new chapter of technology development has recently been initiated by the NASA RPS Program. This effort is considering all dynamic power convertor options, such as Stirling and Brayton cycles. Four convertor development contracts supporting this effort were awarded in 2017. The awarded contracts include two free-piston Stirling, one thermoacoustic Stirling, and one turbo-Brayton design. The technology development contracts each consist of up to three phases: design, fabrication, and test. As of May 2018, all contracts have completed the design phase, and each underwent a design review with an independent review board. Three of the contracts are planned to execute the phase 2 option for fabrication. Convertors manifesting from these development efforts will then undergo independent validation and verification (IV and V) at NASA facilities, which will consist of convertor performance and RPS viability demonstrations. Example tests include launch vibration simulation, performance mapping over the environmental temperature range, and static acceleration exposure. In parallel with this renewed development effort, Glenn is still demonstrating free-piston Stirling convertor technology using assets from previous projects. The Stirling Research Laboratory (SRL) is still operating several convertors from previous development projects, which have similarities and relevance to current contract designs. Four of these are flexure-bearing based and another six are gas bearing based. One of the flexure-bearing convertors has accumulated over 110,000 h of operation and holds the current record for maintenance-free heat-engine run time. Another flexure-bearing convertor was recently manually shut down after 105,620 h of operation, then disassembled and inspected. This inspection produced a wealth of information about the effects of this amount of run time on the technology's components. One of the engineering unit flexure-bearing convertors recently underwent a launch simulation vibration test, a static acceleration exposure up to 20 g, and was then placed on extended operation. Among the gas-bearing convertors, the longest running unit has accumulated over 70,000 h of operation. Four high-fidelity gas-bearing convertors from the ASRG project are still operating continuously for which the longest run time has reached 28,000 h.

Oriti, Salvatore M.↗
NASA NTRS2004

Research and Technology 2003

The NASA Glenn Research Center at Lewis Field, in partnership with U.S. industries, universities, and other Government institutions, is responsible for developing critical technologies that address national priorities in aeropropulsion and space applications. Our work is focused on research for new aeropropulsion technologies, aerospace power, microgravity science (fluids and combustion), electric propulsion, and communications technologies for aeronautics, space, and aerospace applications. As NASA s premier center for aeropropulsion, aerospace power, and turbomachinery, our role is to conduct world-class research and to develop key technologies. We contribute to economic growth and national security through safe, superior, and environmentally compatible U.S. civil and military aircraft propulsion systems. Our Aerospace Power Program supports all NASA Enterprises and major programs, including the International Space Station, Advanced Space Transportation, and new initiatives in human and robotic exploration. Glenn Research Center leads NASA s research in the microgravity science disciplines of fluid physics, combustion science, and acceleration measurement. Almost every space shuttle science mission has had an experiment managed by NASA Glenn, and we have conducted a wide array of similar experiments on the International Space Station. The Glenn staff consists of over 3200 civil service employees and support service contractor personnel. Scientists and engineers comprise more than half of our workforce, with technical specialists, skilled workers, and an administrative staff supporting them. We aggressively strive for technical excellence through continuing education, increased diversity in our workforce, and continuous improvement in our management and business practices so that we can expand the boundaries of aeronautics, space, and aerospace technology. Glenn Research Center is a unique facility located in northeast Ohio. Situated on 350 acres of land adjacent to the Cleveland Hopkins International Airport, Glenn comprises more than 140 buildings, including 24 major facilities and over 500 specialized research and test facilities. Additional facilities are located at Plum Brook Station, which is about 50 miles west of Cleveland. Plum Brook Station has four large, major, world-class facilities for space research available for Government and industry programs. Knowledge is the end product of our activities. The R&T reports help make this knowledge fully available to potential users the aircraft engine industry, the space industry, the energy industry, the automotive industry, the aerospace industry, and others. It is organized so that a broad cross section of the community can readily use it. Each article begins with a short introductory paragraph that should prove valuable for the layperson. These articles summarize the progress made during the year in various technical areas and portray the technical and administrative support associated with Glenn s technology programs. We hope that this information is useful to all. If additional information is desired, readers are encouraged to contact the researchers identified at the end of each article and to visit Glenn on the World Wide Web at http://www.grc.nasa.gov.

Julian Earls↗
NASA NTRS2001

Resources Available for Hazards Analysis of Aerospace Fluids

In recent years, the legislative and executive branches of the federal government have pushed to make government more efficient and responsive to the needs of the marketplace. One of these initiatives, Public Law 104-113, also known as the National Technology Transfer and Advancement Act of 1995 (NTTAA), is designed to accelerate technology transfer to industry and promote government-industry partnership. Summarized, NTTAA states that '... all Federal agencies and departments shall use technical standards that are developed or adopted by voluntary consensus standards bodies, using such technical standards as a means to carry out policy objectives or activities determined by the agencies and departments. Government agencies must now determine if their in-house requirement-setting activities are sufficiently unique that no public interest is served by having them adopted by a voluntary consensus organization (VCO), or if not, to use or develop voluntary consensus standards. The Office of Management and Budget (OMB) is chartered by the law to monitor federal agency progress and report the results to Congress. In response to NTTAA, agency-wide oxygen and hydrogen safety standards sponsored by the NASA Headquarters (HQ) Office of Safety and Mission Assurance (OSMA) were obvious choices for early adoption by VCOs. In 1996, HQ sought assistance from the Johnson Space Center (JSC) White Sands Test Facility (WSTF), the technical lead for development of these safety standards, to evaluate their adoption by VCOs. At that time, WSTF-developed propellant hazards manuals were likewise identified for possible VCO adoption. Subsequently, WSTF was asked to represent NASA for development of an international ISO safety standard for hydrogen use. Concurrent with these WSTF standards activities are related efforts to develop and publish propellant hazards analysis protocols and safety courses for the industrial, propellant use of oxygen, hydrogen, and hypergols. This paper reports on these efforts and describes WSTF's overall voluntary consensus standards program to coordinate the interchange of NASA's propellant hazards and safety information with industry.

Woods, S. S.↗
NASA NTRS2004

High-Temperature Hybrid Rotor Support System Developed

The Army Research Laboratory Vehicle Technology Directorate and the NASA Glenn Research Center demonstrated a unique high-speed, high-temperature rotor support system in September 2003. Advanced turbomachinery is on its way to surpassing the capabilities of rolling-element bearings and conventional dampers. To meet these demands, gas turbine engines of the future will demand increased efficiency and thrust-to-weight ratio, and reduced specific fuel consumption and noise. The more-electric engine replaces oil-lubricated bearings, dampers, gears, and seals with electrical devices. One such device is the magnetic bearing. The Vehicle Technology Directorate and Glenn have demonstrated the operation of a radial magnetic bearing in combination with a hydrostatic bearing at 1000 F at 31,000 rpm (2.3 MDN1). This unique combination takes advantage of a high-temperature rub surface in the event of electrical power loss or sudden overloads. The hydrostatic bearings allow load sharing with the magnetic bearing. The magnetic-hydrostatic bearing combination eliminates wear and high contact stress from sudden acceleration of the rolling-element bearings and overheating. The magnetic bearing enables high damping, adaptive vibration control, and precise rotor positioning, diagnostics, and health monitoring. A model of the test facility used at Glenn for this technology demonstration is shown. A high-temperature heteropolar radial magnetic bearing is located at the center of gravity of the test rotor. There is a 0.022-in. radial air gap between the rotor and stator. Two rub surface hydrostatic bearings were placed on either side of the magnetic bearing. The rotor is supported by a 0.002-in. hydrostatic air film and the magnetic field. The prototype active magnetic bearing cost $24,000 to design and fabricate and a set of four high temperature, rub-surface, hydrostatic bearings cost $28,000. This work was funded by the Turbine-Based Combined Cycle program.

Montague, Gerald T.↗
NASA NTRS2000

Mechanically Induced g-Jitter from Space Station Rotary Joints

The mission of the International Space Station is to provide a working laboratory in orbit for research in engineering, life sciences, and microgravity. Among the microgravity disciplines that are preparing to utilize this international resource are materials processing, combustion, fluid dynamics, biotechnology, and fundamental physics. The Station promises to enable significant advances in each of these areas by making available a research facility in which gravitational and other accelerations, and their corresponding buoyancy and diffusion effects on various physical processes, are orders of magnitude lower than they are on Earth. In order to fulfill this promise, it is not enough for the Space Station to simply replicate a typical terrestrial scientific laboratory in orbit. Although an orbiting laboratory is free of most of the effects of gravitational acceleration by virtue of its free fall condition, it also produces structural vibration or jitter that can interfere with the processes under study. To ensure the quality of the acceleration environment and enable a successful mission, the Space Station Program has limited potential disturbances in two ways: first, by isolating the most sensitive payloads from the vehicle structure, and second, by quieting major disturbances at their sources. The first area, payload isolation, is implemented inside the pressurized modules at the rack level. Sub-rack level isolators have also been developed. This paper addresses the second area, disturbance source limits, for one of the major sources of mechanical noise on the Space Station: the Solar Alpha Rotary Joints. Due to the potential for large disturbances to the microgravity environment, an initial analytical prediction of rotary joint vibration output was made. Key components were identified and tested to validate the analytical predictions. Based on the component test results, the final vibration output of the joints was verified by a test on each fully assembled flight unit. This paper describes the Space Station microgravity requirements, the rotary joint hardware, and the disturbance producing aspects of joint operation. The test setup, instrumentation, test conditions, and results for the component level and system level measurements are described. An overall forcing function that describes the maximum torque imparted to the Station is created based on the test results, and these disturbances are shown to meet the applicable Space Station microgravity requirements.

Boucher, Robert L.↗
NASA NTRS2020

Apollo Next Generation Sample Analysis (ANGSA): A Segue to the Next Era of Lunar Exploration and Sample Return Activities

In the fifty years since the first lunar samples were collected on Apollo 11, significant advancements have taken place in laboratory analysis, planetary science, and astromaterials curation. These advances are now being leveraged for the Apollo Next Generation Sample Analysis (ANGSA) Program, which aims to study specially curated Apollo samples that have never been studied before. Since Apollo 17 in 1972, a great deal has been learned about the Moon, including the unique environments of the poles. Building upon Apollo and remote sensing studies since then, the Artemis Program aims to explore the cold environments near the lunar south pole while achieving the concurrent goals of landing the first woman and the next man on the Moon by 2024. Recent developments for ANGSA have significantly accelerated our readiness for Artemis sample return, particularly in the area of cold sample studies. Four science teams were selected to study cold and/or volatile-bearing samples collected during the Apollo program. These samples have special storage and handling requirements that necessitate their processing in a -20°C environment that meets the Apollo materials and cleanliness requirements. NASA has recently undertaken the development and implementation of a cold sample processing facility to support ANGSA. A similar facility will be needed to process the cold, volatile-bearing samples planned to be returned by Artemis missions; therefore, ANGSA provides excellent preparation for Artemis’ future cold sample processing efforts. We will outline the goals of the ANGSA and Artemis programs, illustrating the complementary nature of the work for both. We will describe the efforts to date in designing, testing, and implementing a cold curation facility that meets the requirements of ANGSA and Apollo curation. We will then outline future work for that facility to reach operational readiness. Finally, we will present the sample collection and curation strategies for Artemis, showing how they overlap and build on ANGSA efforts. The development of cold curation at NASA represents a significant leap in the knowledge, experience, and technologies used in astromaterials curation, opening the door for new investigations of lunar volatiles, impacts, formation processes, prebiotic chemistry, and resource utilization, among many others.

Julie Mitchell↗
NASA NTRSDate not supplied

Investigating Material Behavior in Atmospheric Entry Conditions: Arc-Jet Testing Insights from Meteorite Ablation to High-Temperature Coatings.

Arc-jet testing is an indispensable tool in elucidating the complex interactions materials undergo when subjected to the extreme thermal and mechanical stresses of atmospheric entry. By replicating these harsh conditions, arc-jets enable researchers to explore critical phenomena such as ablation, melting, and spallation, generating invaluable data that informs the development of sophisticated, physics-based models. These models are pivotal not only in predicting material performance for spacecraft re-entry systems but also in assessing the threat posed by celestial bodies as they encounter Earth’s atmosphere. One of the leading facilities for such investigations is the Hypersonic Materials Environmental Test System (HyMETS) at NASA’s Langley Research Center. A pioneering test campaign conducted at HyMETS focused on unraveling the ablation mechanisms of an ordinary chondrite meteorite (Tamdakht H5) and a terrestrial analog (basalt). These studies unveiled distinct material behaviors: Tamdakht demonstrated a remarkably stable melt flow, with mass loss primarily driven by the volatilization of elements such as iron and sodium, whereas basalt exhibited more aggressive surface degradation due to the rapid decomposition of hydrated minerals, culminating in significant spallation and surface material ejection. Beyond meteorite analysis, HyMETS has also been integral in the exploration of advanced Thermal Protection Systems (TPS) such as Phenolic Impregnated Carbon Ablator (PICA), a material with extensive flight heritage in missions like Stardust, Mars Science Laboratory, Mars 2020, and Osiris-REx. PICA, when coated with NuSil CV-1144-0—a polysiloxane resin designed to prevent particle shedding—undergoes a remarkable transformation upon heating. The resin pyrolyzes to form a thin, oxidation-resistant silicon oxycarbide layer that profoundly influences the material’s thermal response through a sophisticated four-stage process. Initially, the silicon oxycarbide acts as a formidable barrier, impeding reactive interactions with the PICA char and effectively suppressing surface temperature rise and material recession. However, as the heating persists, the protective layer decomposes via carbothermal reduction, exposing the underlying char, which in turn leads to a dramatic spike in surface temperature and accelerated material erosion. In the final stage, equilibrium is reached, with recession rates aligning with those of the virgin material. This intricate understanding of PICA-NuSil behavior under extreme conditions offers valuable insights, enhancing material response models and advancing the development of next-generation TPS for space exploration.

Chemistry↗
NASA NTRS2004

NASA Multidimensional Stirling Convertor Code Developed

A high-efficiency Stirling Radioisotope Generator (SRG) for use on potential NASA Space Science missions is being developed by the Department of Energy, Lockheed Martin, Stirling Technology Company, and the NASA Glenn Research Center. These missions may include providing spacecraft onboard electric power for deep space missions or power for unmanned Mars rovers. Glenn is also developing advanced technology for Stirling convertors, aimed at substantially improving the specific power and efficiency of the convertor and the overall power system. Performance and mass improvement goals have been established for second- and third-generation Stirling radioisotope power systems. Multiple efforts are underway to achieve these goals, both in house at Glenn and under various grants and contracts. These efforts include the development of a multidimensional Stirling computational fluid dynamics code, high-temperature materials, advanced controllers, an end-to-end system dynamics model, low-vibration techniques, advanced regenerators, and a lightweight convertor. Under a NASA grant, Cleveland State University (CSU) and its subcontractors, the University of Minnesota (UMN) and Gedeon Associates, have developed a twodimensional computer simulation of a CSUmod Stirling convertor. The CFD-ACE commercial software developed by CFD Research Corp. of Huntsville, Alabama, is being used. The CSUmod is a scaled version of the Stirling Technology Demonstrator Convertor (TDC), which was designed and fabricated by the Stirling Technology Company and is being tested by NASA. The schematic illustrates the structure of this model. Modeled are the fluid-flow and heat-transfer phenomena that occur in the expansion space, the heater, the regenerator, the cooler, the compression space, the surrounding walls, and the moving piston and displacer. In addition, the overall heat transfer, the indicated power, and the efficiency can be calculated. The CSUmod model is being converted to a two-dimensional model of the TDC at NASA Glenn. Validation of the multidimensional Stirling code is an important part of the grant effort. UMN has been generating data in an oscillating-flow test facility using two different test sections: a 90 turn and a cooler/regenerator/heater test section. CSU has created computational fluid dynamics models of both these test sections and has been making comparisons with the data, then improving their models to improve the agreement with the test data. CSU has also been using data available in the literature for code validation. UMN is now preparing to begin fabrication of a new 180 turn test section that will be more representative of certain portions of the Stirling engine geometry. Simulations to almost periodic steady state with the two-dimensional CSUmod model indicate that, to reach periodic steady state on a single 2-GHz desktop computer, 75 to 100 complete simulation cycles would be required and between 1 and 2 months of computer time. Therefore, Glenn has purchased the first 8 computers, of a 64-computer cluster, to be run in parallel to accelerate the simulation. On the basis of CFD Research Corp.'s experience with running the parallelized version of CFD-ACE on their clusters, we estimate that the complete 64-computer cluster will reduce simulation computing time by a factor of about 40. Plans are to continue development of these multidimensional Stirling codes and to use them to study the fluid-flow and heat-transfer phenomena that occur inside Stirling convertors. This is expected to lead to improved thermodynamic loss understanding, onedimensional design and performance codes, and engine performance.

Tew, Roy C.↗
NASA NTRS2012

SCaN Testbed Software Development and Lessons Learned

National Aeronautics and Space Administration (NASA) has developed an on-orbit, adaptable, Software Defined Radio (SDR)Space Telecommunications Radio System (STRS)-based testbed facility to conduct a suite of experiments to advance technologies, reduce risk, and enable future mission capabilities on the International Space Station (ISS). The SCAN Testbed Project will provide NASA, industry, other Government agencies, and academic partners the opportunity to develop and field communications, navigation, and networking technologies in the laboratory and space environment based on reconfigurable, SDR platforms and the STRS Architecture.The SDRs are a new technology for NASA, and the support infrastructure they require is different from legacy, fixed function radios. SDRs offer the ability to reconfigure on-orbit communications by changing software for new waveforms and operating systems to enable new capabilities or fix any anomalies, which was not a previous option. They are not stand alone devices, but required a new approach to effectively control them and flow data. This requires extensive software to be developed to utilize the full potential of these reconfigurable platforms. The paper focuses on development, integration and testing as related to the avionics processor system, and the software required to command, control, monitor, and interact with the SDRs, as well as the other communication payload elements. An extensive effort was required to develop the flight software and meet the NASA requirements for software quality and safety. The flight avionics must be radiation tolerant, and these processors have limited capability in comparison to terrestrial counterparts. A big challenge was that there are three SDRs onboard, and interfacing with multiple SDRs simultaneously complicatesd the effort. The effort also includes ground software, which is a key element for both the command of the payload, and displaying data created by the payload. The verification of the software was an extensive effort. The challenges of specifying a suitable test matrix with reconfigurable systems that offer numerous configurations is highlighted. Since the flight system testing requires methodical, controlled testing that limits risk, a nearly identical ground system to the on-orbit flight system was required to develop the software and write verification procedures before it was installed and tested on the flight system. The development of the SCAN testbed was an accelerated effort to meet launch constraints, and this paper discusses tradeoffs made to balance needed software functionality and still maintain the schedule. Future upgrades are discussed that optimize the avionics and allow experimenters to utilize the SCAN testbed potential.

radio communication↗
NASA NTRS1995

Numerical Simulations of High Enthalpy Pulse Facilities

Axisymmetric flows within shock tubes and expansion tubes are simulated including the effects of finite rate chemistry and both laminar and turbulent boundary layers. The simulations demonstrate the usefulness of computational fluid dynamics for characterizing the flows in high enthalpy pulse facilities. The modeling and numerical requirements necessary to simulate these flows accurately are also discussed. Although there is a large body of analysis which explains and quantifies the boundary layer growth between the shock and the interface in a shock tube, there is a need for more detailed solutions. Phenomena such as thermochemical nonequilibrium. or turbulent transition behind the shock are excluded in the assumptions of Mirels' analysis. Additionally there is inadequate capability to predict the influence of the boundary layer on the expanded gas behind the interface. Quantifying the gas in this region is particularly important in expansion tubes because it is the location of the test gas. Unsteady simulations of the viscous flow in shock tubes are computationally expensive because they must follow features such as a shock wave over the length of the facility and simultaneously resolve the small length scales within the boundary layer. As a result, efficient numerical algorithms are required. The numerical approach of the present work is to solve the axisymmetric gas dynamic equations using an finite-volume formulation where the inviscid fluxes are computed with a upwind TVD scheme. Multiple species equations are included in the formulation so that finite-rate chemistry can be modeled. The simulations cluster grid points at the shock and interface and translate this clustered grid with these features to minimize numerical errors. The solutions are advanced at a CFL number of less than one based on the inviscid gas dynamics. To avoid limitations on the time step due to the viscous terms, these terms are treated implicitly. This requires a block tri-diagonal matrix inversion along each line of cells normal to the wall. The cost of this inversion is more than offset by the larger allowable time step. The source terms representing the finite-rate chemical kinetics are also treated implicitly. An algebraic turbulence model for compressible flow is used. The flow in a low pressure shock tube is computed and the results are compared with Mirels'analysis. The driven gas is nitrogen at 70 Pa, and the incident shock speed is approximately 2.9 km/sec so that there is little dissociation. The simulations include a laminar boundary layer and are run until the limiting flow regime is achieved. At this limit, the shock and interface travel at the same velocity because the amount of driven gas between these two features remains the same: the mass flow across the shock is equal to the mass of gas being entrained at the interface by the boundary layer. Simulations with several grids are presented to establish the grid independence of the solution, Good agreement is achieved between Mirels' correlations and the computations. This is expected since the flow conditions are chosen to be consistent with the assumptions used in Mirels' analysis. This comparison adds credibility to the numerical approach and highlights some of the differences between the theory and the detailed simulations. In addition, simulations of the HYPULSE expansion tube are presented for two operating conditions and the computations are compared to experimental data. The operating gas for both cases is nitrogen. One test condition is at a total enthalpy of 15.2 MJ/Kg and a relatively low pressure of 2 kPa. This case is characterized by a laminar boundary layer and significant chemical nonequilibrium. in the acceleration gas. The second test condition is at a total enthalpy of 10.2 MJ/Kg and a pressure of 38 kPa and is characterized by a turbulent boundary layer. The simulations compare well with experiment and reveal that the nonuniformity in pressure observed during the test time is related to variations in the boundary layer displacement thickness.

Wilson, Gregory J.↗