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NASA's Space Launch System Begins Integration, Stacking in Preparation for Artemis I Launch

The Artemis era of human lunar exploration is nearing take-off as NASA’s new super heavy-lift launch vehicle, the Space Launch System (SLS), begins stack-ing and integration operations in mid-2020 at Kennedy Space Center (KSC) in Florida. With a planned upgrade path to progressively more powerful vehicles and availability in crew and cargo configurations, SLS provides a unique and flexible launch solution to send crew, large-scale infrastructure and robotic probes to deep space. The SLS Block 1 vehicle, the initial variant to fly, is optimized for lunar missions with a proven propulsion system consisting of four liquid hydrogen (LH2)/liquid oxygen (LOX)-fed RS-25 engines and twin five-segment solid rocket boosters (SRBs). The Block 1 vehicle can also be outfitted with an industry-standard 5 m-class payload fairing (the “cargo” configuration) and will launch at least 27 metric tons (t) of mass to trans-lunar injection (TLI). SLS is the backbone of NASA’s Artemis program, which will return the agency’s human spaceflight program to the Moon for the first time since 1972. For the Artemis I mission, SLS will send an uncrewed Orion spacecraft to TLI, where it will enter a distant retrograde lunar orbit and fly 38,000 nmi past the Moon – farther than any spacecraft built for humans has ever traveled. The SLS Block 1 vehicle for Artemis I completed manufacturing in 2019. Several elements, including the upper stage, have been delivered to the Exploration Ground Systems (EGS) program at KSC and are being prepped for integration and stack-ing. The five-segment solid rocket boosters – the largest and most powerful ever built for flight – are also complete. The booster motor segments for the Artemis I flight are scheduled to ship from prime contractor Northrop Grumman’s Utah facilities and begin stacking and integration at KSC in June 2020. The SLS core stage is the largest rocket stage NASA has ever built in terms of volume and height, and includes the avionics and the tanks that feed cryogenic propellant to the four RS-25s (formerly Space Shuttle Main Engines [SSMEs]). They have been modified with an updated controller and nozzle insulation to protect them from the hotter launch environment. The SLS core stage is currently being test-ed at NASA’s Stennis Space Center (SSC) in a series of “green run” tests to verify it meets design and performance requirements. Following the green run test series, which is scheduled to culminate with a full-duration hot-fire of the four RS-25 engines, the core stage will ship to KSC and be stacked between the sol-id rocket boosters in the Vehicle Assembly Building (VAB). Integration of the vehicle will continue with the upper stage, known as the Interim Cryogenic Propulsion Stage (ICPS) and the Launch Vehicle Stage Adapter (LVSA) on the core stage. Another adapter, the Orion Stage Adapter (OSA), connects SLS to Orion and provides housing for 13 6U CubeSat payloads manifested on Artemis I. The CubeSats will be released in deep space after Orion separates from the vehicle, and the flight marks the first ride share opportunity for independent small-sats to deep space. The second major SLS variant to come online, Block 1B, replaces the single-engine ICPS with a four-engine LH2/LOX Exploration Upper Stage (EUS). This more powerful upper stage, along with other vehicle up-grades, will enable the Block 1B vehicle to launch 38-42 t to TLI, depending on crew or cargo configuration. The final evolution of the vehicle, Block 2, will onramp evolved solid rocket boosters to increase mass to TLI to 43-46 t, de-pending on crew or cargo configuration. The Block 1B/Block 2 vehicles can be outfitted with an 8.4 m-diameter payload fairing in 19.1 m or 27.4 m lengths, to provide unprecedented volume for payloads. With the initial Block 1 vehicle completely manufactured and the core stage in final testing before shipping to KSC, the SLS Program and its industry partners have made significant progress manufacturing subsequent vehicles. For the second Block 1 vehicle, the solid rocket motor segments are complete, as are the RS-25 engines with controllers. All five major components of the Artemis II core stage – the forward skirt, LOX and LH2 tanks, intertank and engine section – are manufactured and technicians are installing subsystems at NASA’s rocket factory, Michoud Assembly Facility. The RL-10 engine for the Artemis II ICPS is complete and panels have been machined for its LH2 tank. In addition, panels are machined for the vehicle’s two adapters, with welding scheduled to begin in summer 2020. Flight hard-ware is also in production for the third SLS vehicle, with several booster motor segments cast. The pace of development on the EUS has increased, with the goal to complete Critical Design Review (CDR) in December 2020. Several EUS test rings have been machined at Michoud. The EUS is designed to exe-cute a variety of missions – human spaceflight, deployment of deep-space infra-structure, or high-C3 missions to the outer solar system – with crew and cargo configurations available beginning in the mid-2020s. The near-term goal for the nation’s powerful new space exploration asset, however, is to launch the Arte-mis program, and send the first woman and the next man to the lunar surface. At the Astrodynamics Specialist Conference, the SLS program will update the community on the progress of the initial Block 1 vehicle in final green run test-ing, integration and stacking. In addition, this paper will provide an update to the community on the manufacturing status of subsequent Block 1 and Block 1B vehicles.

Steve Creech↗
DOE OSTI2021

Selective penetration behavior of microgels in superpermeable channels and reservoir matrices

Gel treatment is an effective way to attack excessive water production in many mature oilfields around the world. Selective penetration is desired for successful gel treatments. That is, gel materials should easily penetrate the target zones (i.e., channeling features such as superpermeable channels) without entering/damaging the nontarget zones (i.e., reservoir matrices or oil zones). This study revealed that presence of threshold penetration pressure (ΔP th ) was responsible for selective penetration behavior of tested microgels. The concept of ΔP th was utilized to figure out favorable working conditions for effective gel treatments. Microgel dispersions were injected into superpermeable (super-k) sandpacks (mimicking super-k channels in reservoirs, 60–221 darcies), heterogeneous models with super-k channels (79–230 darcies), and sandstone cores (mimicking reservoir matrices, 50–5000 md). The results demonstrated that a minimum differential driving pressure (i.e., threshold penetration pressure, ΔP th ) was required to push microgel particles to penetrate channels or matrices. The critical penetration behavior was closely related to the particle/pore size ratio. Low ΔP th at smaller particle/pore ratios was beneficial to allow easy penetration of gel materials into the channeling zones. On the contrary, high ΔPth at larger particle/pore ratios was desirable to prevent gel materials from massively invading and damaging the matrices. Instead, the gel particles accumulated at the inlet surface, and a gel cake was gradually formed. The cake further prevented the invasion of the gels. The cake could be removed by chemical breakers to resume the injectivity/productivity of the matrices. Correlations were developed to describe the relationship between ΔP th and particle/pore ratio. A distinct transition was identified at the particle/pore ratio of about 3. This research could help identify the favorable conditions to achieve successful gel treatments. In an effective conformance treatment, the particle/pore ratio in the channel should be sufficiently low to allow easy penetration of gel materials into the channel (e.g., particle/pore ratio<2 in this study). Meanwhile, the particle/pore ratio in the matrix should be large enough to support a high ΔP th and thus prevent massive gel invasion into the matrix. This study advances the current pore scale studies (a single particle passing through a single channel) to Darcy-scale characterization.

02 PETROLEUM↗
NASA NTRS2000

[Growth of wheat from seed-to-seed in space flight]

In our earlier space experiment with super dwarf wheat we found the spikes developed in space to be barren. The cause of the full crop sterility was sensitivity of this wheat species to the ethylene concentration of 0.3-0.8 mg/m3 during the experiment. The follow-up ground experiments were made to identify species of dwarf wheat that could be raised in space greenhouse Svet and are distinguished by partial tolerance of their reproductive organs to elevated ethylene in air. The choice fell on the USU-Apogee cultivar specially developed for planting in growth chambers as an integral part of various bioregenerative life support systems, including the space ones. An experiment with wheat Apogee was performed in greenhouse Svet on board MIR. The period of the full crop vegetation cycle was not significantly altered under the spaceflight conditions. The experiment yielded 508 seeds from 12 plants, i.e. by 38% less than in laboratory experiments and by 69% more as compared with results of growing crops in ethylene-contaminated atmosphere (1 mg/m3). Mass of the space seeds was low if compared with the laboratory crops. This was the first time when the feasibility of gathering seeds from wheat that had passed the whole vegetation cycle in space flight was demonstrated. The experiment will give mightly impetus to the advancement of research on space biological LSS and gravitational biology.

long duration↗
NASA NTRS1997

Seedborne fungal contamination: consequences in space-grown wheat

Plants grown in microgravity are subject to many environmental stresses that may promote microbial growth and result in disease symptoms. Wheat (cv. Super Dwarf) recovered from an 8-day mission aboard a NASA (National Aeronautics and Space Administration) space shuttle showed disease symptoms, including girdling of leaf sheaths and chlorosis and necrosis of leaf and root tissues. A Neotyphodium species was isolated from the seed and leaf sheaths of symptomatic wheat used in the spaceflight mission. Certain isozymes of a peroxidase unique to extracts from the microgravity-grown plants were observed in extracts from earth-grown Neotyphodium-infected plants but were not present in noninfected wheat. The endophytic fungus was eliminated from the wheat seed by prolonged heat treatment at 50 degrees C followed by washes with water at 50 degrees C. Plants from wheat seed infected with the Neotyphodium endophyte were symptomless when grown under greenhouse conditions, whereas symptoms appeared after only 4 days of growth in closed containers. Disease spread from an infected plant to noninfected plants in closed containers. Dispersion via spores was found on asymptomatic plants at distances of 7 to 18 cm from infected plants. The size and shape of the conidia, mycelia, and phialide-bearing structures and the ability to grow rapidly on carbohydrates, especially xylose, resembled the characteristics of N. chilense, which is pathogenic on orchard grass, Doctylis glomerati. The Neotyphodium wheat isolate caused disease symptoms on other cereals (wheat cv. Malcolm, orchard grass, barley, and maize) grown in closed containers.

NASA Discipline Plant Biology↗
DOE OSTI2016

Final report of “A Detailed Study of the Physical Mechanisms Controlling CO2-Brine Capillary Trapping in the Subsurface” (University of Arizona, DE-SC0006696)

Carbon capture and storage (CCS) of carbon dioxide emissions generated by production or combustion of fossil fuels is a technologically viable means to reduce the build-up of CO2 in the atmosphere and oceans. Using advantages of scale and location, CCS is particularly suitable for large point sources near ubiquitous deep saline aquifers, depleted gas reservoirs, or at production reservoirs for enhanced oil recovery (EOR). In the BES-funded research project, Oregon State University (OSU) carried out capillary trapping experiments with proxy fluids that mimic the properties of the scCO2/brine system under ambient temperatures and pressures, and successfully developed a unique and novel x-ray compatible, high-pressure, elevated temperature setup to study the scCO2/brine system under challenging reservoir conditions. Both methodologies were applied to a variety of porous media, including synthetic (glass bead) and geologic (Bentheimer sandstone) materials. The University of Arizona (UA) developed pore-scale lattice Boltzmann (LB) models which are able to handle the experimental conditions for proxy fluids, as well as the scCO2/brine system, that are capable of simulating permeability in volumes of tens of millions of fluid elements. We reached the following summary findings (main institute indicated): 1. (OSU/UA) To understand capillary trapping in a multiphase fluid-porous medium system, the system must be analyzed from a pore-scale force balance perspective; trapping can be enhanced by manipulating wetting and nonwetting phase fluid properties. 2. (OSU) Pore-scale fluid connectivity and topology has a clear and direct effect on nonwetting phase capillary trapping efficiency. 3. (OSU) Rock type and flow regime also have a pronounced effects on capillary trapping. 4. (OSU/UA) There is a predictable relationship between NWP connectivity and NWP saturation, which allows for development of injection strategies that optimize trapping. The commonly used Land model (Land, 1968) does not predict amount of trapped NWP accurately. 5. (UA) There are ambiguities regarding the segmentation of large-volume gray-scale CT data into pore-volumes suitable for pore-scale modeling. Simulated permeabilities vary by three orders of magnitude and do not resemble observed values very well. Small-volume synchrotron-based CT data (such as produced by OSU) does not suffer significantly from segmentation ambiguities. 6. (UA) A standard properly parameterized Shan-Chen model LB model is useful for simulating porous media with proxy fluids as well as the scCO2/brine system and produces results that are consistent with tomographic observations. 7. (UA) A LB model with fluid-interactions defined by a (modified) Peng-Robinson Equation of State is able to handle the scCO2/brine system with variable solid phase wettability. This model is numerically stable at temperatures between 0 and 250 °C and pressures between 3 and 50 MPa, and produces appropriate densities above the critical point of CO2 and exhibits three-phase separation below. Based on above findings OSU and UA have proposed continued experimentation and pore-scale modeling of the scCO2/brine system. The reported research has extensively covered capillary trapping using proxy fluids, but due to limited beam-time availability we were unable to apply our high-pressure CO2 setup to sufficient variation in fluid properties, and initial scCO2 connectivity. New data will also allow us to test, calibrate and apply our LB models to reservoir conditions beyond those that are currently feasible experimentally. Such experiments and simulations will also allow us to provide information how suitable proxy fluids are for the scCO2/brine system. We believe it would be worthwhile to pursue the following new research questions: 1. What are the fundamental differences in the physics underlying capillary trapping at ambient vs. supercritical conditions? 2. Do newly developed pore-scale trapping interactions and relationships translate to continuum scales? A motivation for these questions was elaborated in “Capillary Trapping of Super-Critical CO2: Linking Pore and Continuum Scales to Verify new Relationships” that was submitted to DOE-BES in 2015.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Welding of Haynes 282 to Steels to Enable Modular Rotors for Advanced Ultra Super-Critical Steam Turbines

Steam turbines for an Advanced Ultra Super Critical (AUSC) fossil fired power plant will operate at temperatures well above those of current commercial steam cycles with inlet temperatures more than 760 C , which is beyond the capabilities of alloy steels presently used for steam turbine applications and requires advanced materials. Large components such as steam turbine rotors may be made of nickel based super alloys such as Haynes 282 (H282). However, monolithic forgings of superalloys in the sizes required for large steam turbines rotors can be prohibitively expensive besides many technical challenges. To minimize cost and alleviate the related technical challenges, superalloy use needs to be limited to locations on the steam turbine rotor where strength and temperature requirements cannot be met by conventional steels. This is possible if nickel-based superalloys can be successfully welded to steels and the related technical challenges - machining parts made of dissimilar welded materials, non-destructive examination of such welds for flaw detection; and, material properties of such hybrid components – are sufficiently addressed. In this technology development project, we successfully welded H282 to plates up to ~ 75 mm (~ 3 inches) to a 3.5NiCrMoV steel of similar thickness. Advanced ultrasonic inspection technique called Phased Array Ultrasonic Testing (PAUT) was employed to examine the dissimilar H282-Steel welds, into which flat bottomed side drilled holes (SDH) of various diameters were introduced, to determine the minimum detectable feature sizes; it was shown that with PAUT SDH of dia. down to 0.5 mm could be detected in the base alloys and SDH with dia. down to 2.4 mm could be detected in the weld metal under multiple orientations successfully. An autonomous machining process monitoring system was developed and demonstrated whereby the forces acting on the cutting tool could be actively monitored as the cutting tool transitioned from H282 to Steel across the weld using which the machining parameters can be potentially altered without interruption to extend tool life. This project successfully achieved its objectives of - i. Developing a welding methodology and viable welding geometries, to successfully join H282 to steel 3.5CrMoNiV steel to enable manufacture of modular steam turbine rotors for AUSC applications (conditions of at least 760 °Celsius and 3,100 psia (pounds per square inch absolute pressure) and evaluate the material properties of the welded specimen. ii. Employ the advanced ultrasonic inspection technique to the dissimilar weld metal joint and determine the minimum detectable feature sizes. iii. Develop effective machining techniques to machine such hybrid structures with online tool force monitoring and effect machine state metrics for optimal results.

20 FOSSIL-FUELED POWER PLANTS↗