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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 559 records · Page 31

Risk Trade-Space Analysis for Safe Human Expeditions to Mars

We assessed the integrated safety, health, and performance risk to crews on long-duration missions, specifically to Mars. Using a systems approach rather than one focused on individual countermeasures, we examined the trade space around several such risks to identify high-potential risk mitigation strategies and characterize aspects of Mars mission architectures that could lower aggregated risk. Current Mars Design Reference missions would require durations well over two years and would increase crew exposure to radiation and microgravity well beyond ISS levels, likely resulting in significantly reduced performance beyond our current capability to mitigate that could jeopardize mission success. A “fast Mars transit” round-trip mission concept was studied using an innovative flight dynamics approach to quantify the minimum total mission energy required for a Mars transit with total mission duration less than 400 days. This approach holds promise for sending humans to Mars and returning them safely with acceptable, potentially mitigatable, exposure to microgravity and radiation using current or near-term technologies. The fast transit concept would also result in fewer time-driven vehicle failures and enable sustainable deployment of humans and infrastructure to Mars on a regular cadence, allowing steady exploration and colonization of Mars. Finally, we conclude that reliance on the Low Earth Orbit (LEO) mission operations paradigm – i.e., one of near-complete real-time dependence on experts at Mission Control to manage the combined state of the mission, vehicle, and crew – is high risk given the communication delays and limited resupply of any Mars mission, and this risk is not eliminated by the shorter missions durations of fast transit scenarios. Based on historical trends, it is highly likely that the crew will face a high-consequence problem of uncertain origin during Mars transit when ground support will be greatly reduced. While it may be possible to reduce anomaly rates through improved reliability analysis and testing, and to reduce anomaly impacts through added robustness, such mitigations address only known failure modes and known uncertainties. Therefore, a radical shift in the Human-Systems Integration Architecture (HSIA) that defines the operational paradigm, systems design, and human-systems interactions is required to improve the risk posture to an acceptable level regardless of mission duration.

Mars↗

High Temperature Devices for Aerospace Applications

This presentation will overview important new capabilities and benefits that next-generation higher temperature electronics promise for a variety of aerospace systems and missions. Initial aerospace infusions of higher temperature electronics to be discussed include jet engines and the prolonged robotic exploration of the Venus surface. Complete redesign of systems compared to prior conventional electronics practices would yield the most revolutionary benefits. However, the inherent higher risk and expense associated with new technology adoption will likely drive a more evolutionary technology infusion process, especially since flight qualification demands large safety margins and testing that ensures reliable operation for far longer than actual mission duration. SiC pn-junction based devices are inherently capable of the most durable operation at the highest application temperatures compared other transistor technologies, but such integrated circuits (ICs) will never achieve integration levels near today’s silicon ICs. Extreme temperature high-power devices will also be de-rated compared to room-temperature performance. While the high temperature market will always be small compared to the conventional temperature mass-market, compatibility and leveraging of existing foundry manufacturing is vital to the establishment of a sustainable high temperature electronics ecosystem sufficient to significantly improve aerospace systems.

High Temperature↗

Temperature Variation Analysis of the STIM300 Inertial Measurement Unit

A key navigation instrument found on most autonomous and semi-autonomous platforms is the inertial measurement unit (IMU). This type of sensor is a combination of microelectromechanical systems (MEMS) that provide inertial information to the navigation system. Typical MEMS hardware include a gyroscope and an accelerometer (for rates and accelerations, respectively) within a single platform. The Near Earth Asteroid (NEA) Scout mission, slated to launch in October of 2018 (Author’s note: NEA Scout ultimately launch on November 16, 2022), carries an on-board IMU from Sensonor. This particular model has yet to see spaceflight, and questions about its on-orbit reliability remain. Dynamic tests were produced in the summer of 2016 by a visiting faculty member from Arkansas Tech University, Daniel Bullock. During these experiments, concerns about the noise characteristics of the sensor were raised, specifically relating to how temperature fluctuations affected the unit. It was found that the IMU took an extended period of time before reaching an internal steady state temperature. These tests often displayed large temperature variations, making the calculation of noise characteristics, such as bias drift, difficult to attribute entirely to noise. Static and dynamic tests were re-performed under more stringent constraints on temperature. Tests reported herein conclude that the IMU is adequately capable of providing inertial information for the NEA Scout mission.

Ivan Rodrigues Bertaska↗

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall informfuture iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300 degrees C over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall inform future iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300degC over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall inform future iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300 C over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

The Significance of Breakdown Voltages for Quality Assurance of Low-Voltage BME Ceramic Capacitors

Application of thin dielectric, base metal electrode (BME) ceramic capacitors for high-reliability applications requires development of testing procedures that can assure high quality and reliability of the parts. In this work, distributions of breakdown voltages (VBR) in variety of low-voltage BME multilayer ceramic capacitors (MLCCs) have been measured and analyzed. It has been shown that analysis of the distributions can indicate the proportion of defective parts in the lot and significance of the defects. Variations of the distributions after solder dip testing allow for an assessment of the robustness of capacitors to soldering-related stresses. The drawbacks of the existing screening and qualification methods to reveal defects in high-value, low-voltage MLCCs and the importance of VBR measurements are discussed. Analysis has shown that due to a larger concentration of oxygen vacancies, defect-related degradation of the insulation resistance (IR) and failures are more likely in BME compared to the precious metal electrode (PME) capacitors.

reliability↗

Reliability analysis

The objective was to search for and demonstrate approaches and concepts for fast wafer probe tests of mechanisms affecting the reliability of MOS technology and, based on these, develop and optimize test chips and test procedures. Progress is reported on four important wafer-level reliability problems: gate-oxide radiation hardness; hot-electron effects; time-dependence dielectric breakdown; and electromigration.

Source record↗

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

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

Technology Transfer↗

Limitations of Reliability for Long-Endurance Human Spaceflight

Long-endurance human spaceflight - such as missions to Mars or its moons - will present a never-before-seen maintenance logistics challenge. Crews will be in space for longer and be farther way from Earth than ever before. Resupply and abort options will be heavily constrained, and will have timescales much longer than current and past experience. Spare parts and/or redundant systems will have to be included to reduce risk. However, the high cost of transportation means that this risk reduction must be achieved while also minimizing mass. The concept of increasing system and component reliability is commonly discussed as a means to reduce risk and mass by reducing the probability that components will fail during a mission. While increased reliability can reduce maintenance logistics mass requirements, the rate of mass reduction decreases over time. In addition, reliability growth requires increased test time and cost. This paper assesses trends in test time requirements, cost, and maintenance logistics mass savings as a function of increase in Mean Time Between Failures (MTBF) for some or all of the components in a system. In general, reliability growth results in superlinear growth in test time requirements, exponential growth in cost, and sublinear benefits (in terms of logistics mass saved). These trends indicate that it is unlikely that reliability growth alone will be a cost-effective approach to maintenance logistics mass reduction and risk mitigation for long-endurance missions. This paper discusses these trends as well as other options to reduce logistics mass such as direct reduction of part mass, commonality, or In-Space Manufacturing (ISM). Overall, it is likely that some combination of all available options - including reliability growth - will be required to reduce mass and mitigate risk for future deep space missions.

Owens, Andrew C.↗

Ultrasonic Washer–Dryer System for Space Habitats: Design Upgrades and Parabolic Flight Readiness

Clothing makes up nearly 25% of all non-food supplies sent to the International Space Station (ISS). To support sustainable human missions in deep space, NASA’s Life Support and Habitation Systems Focus Area looks to advance technologies to support and improve logistics. Our team is creating a compact ultrasonic clothing washer/dryer system that bypasses traditional limitations and is suitable for space. Thermal drying uses a lot of energy to evaporate water, while our ultrasonic drying method offers a quicker, more efficient alternative. It uses piezoelectric transducers to vibrate textiles at the micron scale, mechanically removing water as cold mist rather than evaporating it. This speeds up drying and reduces energy use, no matter the fabric makeup. This paper details recent upgrades to a full-scale ultrasonic washer–dryer system, readying it for parabolic flight testing. Improvements include an enhanced human–machine interface, better packaging, and optimized performance and control. We also present extensive pre-flight ground tests conducted to ensure reliability and identify potential risks. Collaborating with P&G, we report preliminary cleaning tests using various detergents. These results lay a crucial foundation for the laundry system designed specifically for space. By cutting clothing-related payload and waste by over 97%, this technology supports long-term human exploration missions on the ISS, the Moon, Mars, and beyond.

Ultrasonic↗

Ultrasonic Washer–Dryer System for Space Habitats: Design Upgrades and Parabolic Flight Readiness

Clothing makes up nearly 25% of all non-food supplies sent to the International Space Station (ISS). To support sustainable human missions in deep space, NASA’s Life Support and Habitation Systems Focus Area looks to advance technologies to support and improve logistics. Our team is creating a compact ultrasonic clothing washer/dryer system that bypasses traditional limitations and is suitable for space. Thermal drying uses a lot of energy to evaporate water, while our ultrasonic drying method offers a quicker, more efficient alternative. It uses piezoelectric transducers to vibrate textiles at the micron scale, mechanically removing water as cold mist rather than evaporating it. This speeds up drying and reduces energy use, no matter the fabric makeup. This paper details recent upgrades to a full-scale ultrasonic washer–dryer system, readying it for parabolic flight testing. Improvements include an enhanced human–machine interface, better packaging, and optimized performance and control. We also present extensive pre-flight ground tests conducted to ensure reliability and identify potential risks. Collaborating with P&G, we report preliminary cleaning tests using various detergents. These results lay a crucial foundation for the laundry system designed specifically for space. By cutting clothing-related payload and waste by over 97%, this technology supports long-term human exploration missions on the ISS, the Moon, Mars, and beyond.

Laundry↗

Wafer level reliability for high-performance VLSI design

As very large scale integration architecture requires higher package density, reliability of these devices has approached a critical level. Previous processing techniques allowed a large window for varying reliability. However, as scaling and higher current densities push reliability to its limit, tighter control and instant feedback becomes critical. Several test structures developed to monitor reliability at the wafer level are described. For example, a test structure was developed to monitor metal integrity in seconds as opposed to weeks or months for conventional testing. Another structure monitors mobile ion contamination at critical steps in the process. Thus the reliability jeopardy can be assessed during fabrication preventing defective devices from ever being placed in the field. Most importantly, the reliability can be assessed on each wafer as opposed to an occasional sample.

Root, Bryan J.↗

On protection of Freedom's solar dynamic radiator from the orbital debris environment. Part 2: Further testing and analyses

Presented here are results of a test program undertaken to further define the response of the solar dynamic radiator to hypervelocity impact (HVI). Tests were conducted on representative radiator panels (under ambient, nonoperating conditions) over a range of velocity. Target parameters are also varied. Data indicate that analytical penetration predictions are conservative (i.e., pessimistic) for the specific configuration of the solar dynamic radiator. Test results are used to define the solar dynamic radiator reliability with respect to HVI more rigorously than previous studies. Test data, reliability, and survivability results are presented.

Rhatigan, Jennifer L.↗

On protection of Freedom's solar dynamic radiator from the orbital debris environment. II - Further testing and analyses

Presented here are results of a test program undertaken to further define the response of the solar dynamic radiator to hypervelocity impact (HVI). Tests were conducted on representative radiator panels (under ambient, nonoperating conditions) over a range of velocity. Target parameters are also varied. Data indicate that analytical penetration predictions are conservative (i.e., pessimistic) for the specific configuration of the solar dynamic radiator. Test results are used to define the solar dynamic radiator reliability with respect to HVI more rigorously than previous studies. Test data, reliability, and survivability results are presented.

Rhatigan, Jennifer L.↗

Hot-Fire Testing of 100 LB(sub F) LOX/LCH4 Reaction Control Engine at Altitude Conditions

Liquid oxygen/liquid methane (LO2/LCH4 ) has recently been viewed as a potential green propulsion system for both the Altair ascent main engine (AME) and reaction control system (RCS). The Propulsion and Cryogenic Advanced Development Project (PCAD) has been tasked by NASA to develop these green propellant systems to enable safe and cost effective exploration missions. However, experience with LO2/LCH4 as a propellant combination is limited, so testing of these systems is critical to demonstrating reliable ignition and performance. A test program of a 100 lb f reaction control engine (RCE) is underway at the Altitude Combustion Stand (ACS) of the NASA Glenn Research Center, with a focus on conducting tests at altitude conditions. These tests include a unique propellant conditioning feed system (PCFS) which allows for the inlet conditions of the propellant to be varied to test warm to subcooled liquid propellant temperatures. Engine performance, including thrust, c* and vacuum specific impulse (I(sub sp,vac)) will be presented as a function of propellant temperature conditions. In general, the engine performed as expected, with higher performance at warmer propellant temperatures but better efficiency at lower propellant temperatures. Mixture ratio effects were inconclusive within the uncertainty bands of data, but qualitatively showed higher performance at lower ratios.

Marshall, William M.↗

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the NASA Space Launch System (SLS) program. Testing was needed because SLS ascent loads are 35% higher than Space Shuttle loads. Objectives of testing were to determine margins of safety, demonstrate reliability, and validate analytical models. Testing combined with analysis was able to show heritage forward skirts were acceptable to use on the SLS program.

Lohrer, J. D.↗