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NASA NTRS2010

Use of DSC and DMA Techniques to Help Investigate a Material Anomaly for PTFE Used in Processing a Piston Cup for the Urine Processor Assembly (UPA) on International Space Station (ISS)

Human urine and flush water are eventually converted into drinking water with the Urine Processor Assembly (UPA) aboard the International Space Station (ISS). This conversion is made possible through the Distillation Assembly (DA) of the UPA. One component of the DA is a molded circular piston cup made of virgin polytetrafluoroethylene (PTFE). The piston cup is assembled to a titanium component using eight fasteners and washers. Molded PTFE produced for spare piston cups in the first quarter of 2010 was different in appearance and texture, and softer than material molded for previous cups. For the suspect newer PTFE material, cup fasteners were tightened to only one-half the required torque value, yet the washers embedded almost halfway into the material. The molded PTFE used in the DA piston cup should be Type II, based on AMS 3667D and ASTM D4894 specifications. The properties of molded PTFE are considerably different between Type I and II materials. Engineers working with the DA thought that if Type I PTFE was molded by mistake instead of Type II material, that could have resulted in the anomalous material properties. Typically, the vendor molds flat sheet PTFE from the same material lot used to mold the piston cups, and tensile testing as part of quality control should verify that the PTFE is Type II material. However, for this discrepant lot of material, such tensile data was not available. Differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) were two of the testing techniques used at the NASA/Marshall Space Flight Center (MSFC) to investigate the anomaly for the PTFE material. Other techniques used on PTFE specimens were: Shore D hardness testing, tensile testing on dog bone specimens and a qualitative estimation of porosity by optical and scanning electron microscopy.

Wingard, Doug↗

NASA NTRS2010

Hollow Fiber Flight Prototype Spacesuit Water Membrane Evaporator Design and Testing

The spacesuit water membrane evaporator (SWME) is being developed to perform thermal control for advanced spacesuits and to take advantage of recent advances in micropore membrane technology. This results in a robust heat-rejection device that is potentially less sensitive to contamination than is the sublimator. The Membrana Celgard X50-215 microporous hollow-fiber (HoFi) membrane was selected after recent extensive testing as the most suitable candidate among commercial alternatives for continued SWME prototype development. The current design was based on a previous design that grouped the fiber layers into stacks, which were separated by small spaces and packaged into a cylindrical shape. This was developed into a full-scale prototype consisting of 14,300 tube bundled into 30 stacks, each of which is formed into a chevron shape and separated by spacers and organized into three sectors of 10 nested stacks. The new design replaced metal components with plastic ones, and has a custom built flight like backpressure valve mounted on the side of the SWME housing to reduce backpressure when fully open. The spacers that provided separation of the chevron fiber stacks were eliminated. Vacuum chamber testing showed improved heat rejection as a function of inlet water temperature and water vapor backpressure compared with the previous design. Other tests pushed the limits of tolerance to freezing and showed suitability to reject heat in a Mars pressure environment with and without a sweep gas. Tolerance to contamination by constituents expected to be found in potable water produced by distillation processes was tested in a conventional way by allowing constituents to accumulate in the coolant as evaporation occurs. For this purpose, the SWME cartridge has endured an equivalent of 30 EVAs exposure and demonstrated minimal performance decline.

Bue, Grant↗

NASA NTRS2010

Cleanser, Detergent, Personal Care Product Pretreatment Evaluation

The purpose of the Cleanser, Detergent, Personal Care Product, and Pretreatment Evaluation & Selection task is to identify the optimal combination of personal hygiene products, crew activities, and pretreatment strategies to provide the crew with sustainable life support practices and a comfortable habitat. Minimal energy, mass, and crew time inputs are desired to recycle wastewater during long duration missions. This document will provide a brief background on the work this past year supporting the ELS Distillation Comparison Test, issues regarding use of the hygiene products originally chosen for the test, methods and results used to select alternative products, and lessons learned from testing.

Adam, Niklas↗

NASA NTRS2006

Fluid Dynamics Assessment of the VPCAR Water Recovery System in Partial and Microgravity

The Vapor Phase Catalytic Ammonia Removal (VPCAR) system is being developed to recycle water for future NASA Exploration Missions. Testing was recently conducted on NASA s C-9B Reduced Gravity Aircraft to determine the microgravity performance of a key component of the VPCAR water recovery system. Six flights were conducted to evaluate the fluid dynamics of the Wiped-Film Rotating Disk (WFRD) distillation component of the VPCAR system in microgravity, focusing on the water delivery method. The experiments utilized a simplified system to study the process of forming a thin film on a disk similar to that in the evaporator section of VPCAR. Fluid issues are present with the current configuration, and the initial alternative configurations were only partial successful in microgravity operation. The underlying causes of these issues are understood, and new alternatives are being designed to rectify the problems.

Niederhaus, Charles↗

NASA NTRS2010

Chemical Analysis Results for Potable Water from ISS Expeditions 21 to 25

The Johnson Space Center Water and Food Analytical Laboratory (WAFAL) performed detailed ground-based analyses of archival water samples for verification of the chemical quality of the International Space Station (ISS) potable water supplies for Expeditions 21 to 25. Over a 14-month period, the Space Shuttle visited the ISS on five occasions to complete construction and deliver supplies. The onboard supplies of potable water available for consumption by the Expeditions 21 to 25 crews consisted of Russian ground-supplied potable water, Russian potable water regenerated from humidity condensate, and US potable water recovered from urine distillate and condensate. Chemical archival water samples that were collected with U.S. hardware during Expeditions 21 to 25 were returned on Shuttle flights STS-129 (ULF3), STS-130 (20A), STS-131 (19A), STS-132 (ULF4) and STS-133 (ULF5), as well as on Soyuz flights 19-22. This paper reports the analytical results for the returned archival water samples and evaluates their compliance with ISS water quality standards. The WAFAL also received and analyzed aliquots of some Russian potable water samples collected in-flight and pre-flight samples of Rodnik potable water delivered to the Station on the Russian Progress vehicle during Expeditions 21 to 25. These additional analytical results are also reported and discussed in this paper.

Straub, John E., II↗

NASA NTRS2010

Total Synthesis of Ionic Liquid Systems for Dissolution of Lunar Simulant

For purposes of Space Resource Utilization, work in the total synthesis of a new ionic liquid system for the extraction of oxygen and metals from lunar soil is studied and described. Reactions were carried out according to procedures found in the chemical literature, analyzed via Thin-Layer Chromatography and 1H Nuclear Magnetic Resonance Spectroscopy and purified via vacuum distillation and rotary evaporation. Upon final analysis via 1H NMR, it was found that while the intermediates of the synthesis had been achieved, unexpected side products were also present. The mechanisms and constraints of the synthesis are described as well as the final results of the project and recommendations for continued study

Sharpe, Robert J.↗

NASA NTRS2010

Accurate Measurements of the Dielectric Constant of Seawater at L Band

This report describes measurements of the dielectric constant of seawater at a frequency of 1.413 GHz that is at the center of the L-Sand radiometric protected frequency spectrum. Aquarius will be sensing the sea surface salinity from space in this band. The objective of the project is to refine the model function for the dielectric constant as a function of salinity and temperature so that remote sensing measurements can be made with the accuracy needed to meet the measurement goals (0.2 psu) of the Aquarius mission. The measurements were made, using a microwave cavity operated in the transmission configuration. The cavity's temperature was accurately regulated to 0.02 C by immersing it in a temperature controlled bath of distilled water and ethanol glycol. Seawater had been purchased from Ocean Scientific International Limited (OS1L) at salinities of 30, 35 and 38 psu. Measurements of these seawater samples were then made over a range of temperatures, from l0 C to 35 C in 5 C intervals. Repeated measurements were made at each temperature and salinity, Mean values and standard deviations were then computed. Total error budgets indicated that the real and imaginary parts of the dielectric constant had a relative accuracy of about l%.

Lang, Roger H.↗

NASA NTRS2011

Hollow Fiber Space Water Membrane Evaporator Flight Prototype Design and Testing

The spacesuit water membrane evaporator (SWME) is being developed to perform thermal control for advanced spacesuits and to take advantage of recent advances in micropore membrane technology. This results in a robust heat-rejection device that is potentially less sensitive to contamination than is the sublimator. The current design was based on a previous design that grouped the fiber layers into stacks, which were separated by small spaces and packaged into a cylindrical shape. This was developed into a full-scale prototype consisting of 14,300 tube bundled into 30 stacks, each of which is formed into a chevron shape and separated by spacers and organized into three sectors of 10 nested stacks. The new design replaced metal components with plastic ones, eliminated the spacers, and has a custom built flight like backpressure valve mounted on the side of the SWME housing to reduce backpressure when fully open. A number of tests were performed in order to improve the strength of the polyurethane header that holds the fibers in place while the system is pressurized. Vacuum chamber testing showed similar heat rejection as a function of inlet water temperature and water vapor backpressure was similar to the previous design. Other tests pushed the limits of tolerance to freezing and showed suitability to reject heat in a Mars pressure environment with and without a sweep gas. Tolerance to contamination by constituents expected to be found in potable water produced by distillation processes was tested in a conventional way by allowing constituents to accumulate in the coolant as evaporation occurs. For this purpose, the SWME cartridge has endured an equivalent of 30 EVAs exposure and demonstrated acceptable performance decline.

Bue, Grant C.↗

NASA NTRS2011

Cleanser, Detergent, Personal Care Product, and Pretreatment Evaluation

Adam, Niklas↗

NASA NTRS2011

Lessons Learned in Engineering

This Contractor Report (CR) is a compilation of Lessons Learned in approximately 55 years of engineering experience by each James C. Blair, Robert S. Ryan, and Luke A. Schutzenhofer. The lessons are the basis of a course on Lessons Learned that has been taught at Marshall Space Flight Center. The lessons are drawn from NASA space projects and are characterized in terms of generic lessons learned from the project experience, which are further distilled into overarching principles that can be applied to future projects. Included are discussions of the overarching principles followed by a listing of the lessons associated with that principle. The lesson with sub-lessons are stated along with a listing of the project problems the lesson is drawn from, then each problem is illustrated and discussed, with conclusions drawn in terms of Lessons Learned. The purpose of this CR is to provide principles learned from past aerospace experience to help achieve greater success in future programs, and identify application of these principles to space systems design. The problems experienced provide insight into the engineering process and are examples of the subtleties one experiences performing engineering design, manufacturing, and operations.

Blair, J. C.↗

NASA NTRS2011

Lessons Learned in Engineering

Blair, James C.↗

NASA NTRS2011

Chemical Analysis Results for Potable Water from ISS Expeditions 21 Through 25

The Johnson Space Center Water and Food Analytical Laboratory (WAFAL) performed detailed ground-based analyses of archival water samples for verification of the chemical quality of the International Space Station (ISS) potable water supplies for Expeditions 21 through 25. Over a 14-month period the Space Shuttle visited the ISS on four occasions to complete construction and deliver supplies. The onboard supplies of potable water available for consumption by the Expeditions 21 to 25 crews consisted of Russian ground-supplied potable water, Russian potable water regenerated from humidity condensate, and US potable water recovered from urine distillate and condensate. Chemical archival water samples that were collected with U.S. hardware during Expeditions 21 to 25 were returned on Shuttle flights STS-129 (ULF3), STS-130 (20A), STS-131 (19A), and STS-132 (ULF4), as well as on Soyuz flights 19-23. This paper reports the analytical results for these returned potable water archival samples and their compliance with ISS water quality standards.

Straub, John E., II↗

NASA NTRS2006

NASA Tech Briefs, October 2006

Topics covered include: Protein Sensors Based on Optical Ring Resonators; Phase Sensor for Aligning a Segmented Telescope Mirror; Control Software for Advanced Video Guidance Sensor; Generating Control Commands From Gestures Sensed by EMG; Multiple-Flat-Panel System Displays Multidimensional Data; 3D X-Ray Luggage-Screening System; Probe Station and Near-Field Scanner for Testing Antennas; Photodetector Arrays for Multicolor Visible/Infrared Imaging; Semiconductor Bolometers Give Background-Limited Performance; Multichannel X-Band Dielectric-Resonator Oscillator; Automatic Alignment of Displacement-Measuring Interferometer; Earth Observing System Data Gateway; Power User Interface; Mercury Shopping Cart Interface; Cassini Archive Tracking System; Architecture Adaptive Computing Environment; Computing Fault Displacements from Surface Deformations; Oxygen-Permeable, Hydrophobic Membranes of Silanized alpha-Al2O3; SiC Composite Turbine Vanes; Retaining Device for the Interior Structure of a Spacecraft Payload; Tool for Torquing Circular Electrical-Connector Collars; System for Continuous Deaeration of Hydraulic Oil; Solar-Powered Cooler and Heater for an Automobile Interior; Improved Oxygen-Beam Texturing of Glucose-Monitoring Optics; Tool for Two Types of Friction Stir Welding; Stationary Apparatus Would Apply Forces of Walking to Feet; Instrument Would Detect and Collect Biological Aerosols; Boundary Condition for Modeling Semiconductor Nanostructures; Miniature Distillation Column for Producing LOX From Air; Even Illumination from Fiber-Optic-Coupled Laser Diodes; Optically Driven Deformable Mirrors; Algorithm for Automated Detection of Edges of Clouds; Exploiting Quantum Resonance to Solve Combinatorial Problems; Hybrid Terrain Database; On Release of Microbe-Laden Particles from Mars Landers; A Concept for Run-Time Support of the Chapel Language; Thermoelectric Inhomogeneities in (Ag(sub 1-y)SbTe2)(sub x)(PbTe)(sub 1-x); and Spacecraft Escape Capsule.

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NASA NTRS2005

PETIs as High-Temperature Resin-Transfer-Molding Materials

Compositions of, and processes for fabricating, high-temperature composite materials from phenylethynyl-terminated imide (PETI) oligomers by resin-transfer molding (RTM) and resin infusion have been developed. Composites having a combination of excellent mechanical properties and long-term high-temperature stability have been readily fabricated. These materials are particularly useful for the fabrication of high-temperature structures for jet-engine components, structural components on highspeed aircraft, spacecraft, and missiles. Phenylethynyl-terminated amide acid oligomers that are precursors of PETI oligomers are easily made through the reaction of a mixture of aromatic diamines with aromatic dianhydrides at high stoichiometric offsets and 4-phenylethynylphthalic anhydride (PEPA) as an end-capper in a polar solvent such as N-methylpyrrolidinone (NMP). These oligomers are subsequently cyclodehydrated -- for example, by heating the solution in the presence of toluene to remove the water by azeotropic distillation to form low-molecular-weight imide oligomers. More precisely, what is obtained is a mixture of PETI oligomeric species, spanning a range of molecular weights, that exhibits a stable melt viscosity of less than approximately 60 poise (and generally less than 10 poise) at a temperature below 300 deg C. After curing of the oligomers at a temperature of 371 deg C, the resulting polymer can have a glass-transition temperature (Tg) as high as 375 C, the exact value depending on the compositions.

Connell, John N.↗

NASA NTRS2005

Spill-Resistant Alkali-Metal-Vapor Dispenser

A spill-resistant vessel has been developed for dispensing an alkali-metal vapor. Vapors of alkali metals (most commonly, cesium or rubidium, both of which melt at temperatures slightly above room temperature) are needed for atomic frequency standards, experiments in spectroscopy, and experiments in laser cooling. Although the present spill-resistant alkali-metal dispenser was originally intended for use in the low-gravity environment of outer space, it can also be used in normal Earth gravitation: indeed, its utility as a vapor source was confirmed by use of cesium in a ground apparatus. The vessel is made of copper. It consists of an assembly of cylinders and flanges, shown in the figure. The uppermost cylinder is a fill tube. Initially, the vessel is evacuated, the alkali metal charge is distilled into the bottom of the vessel, and then the fill tube is pinched closed to form a vacuum seal. The innermost cylinder serves as the outlet for the vapor, yet prevents spilling by protruding above the surface of the alkali metal, no matter which way or how far the vessel is tilted. In the event (unlikely in normal Earth gravitation) that any drops of molten alkali metal have been shaken loose by vibration and are floating freely, a mesh cap on top of the inner cylinder prevents the drops from drifting out with the vapor. Liquid containment of the equivalent of 1.2 grams of cesium was confirmed for all orientations with rubbing alcohol in one of the prototypes later used with cesium.

Klipstein, William↗

NASA NTRS2004

Ultraviolet-Absorption Spectroscopic Biofilm Monitor

An ultraviolet-absorption spectrometer system has been developed as a prototype instrument to be used in continuous, real-time monitoring to detect the growth of biofilms. Such monitoring is desirable because biofilms are often harmful. For example, biofilms in potable-water and hydroponic systems act as both sources of pathogenic bacteria that resist biocides and as a mechanism for deterioration (including corrosion) of pipes. Biofilms formed from several types of hazardous bacteria can thrive in both plant-growth solutions and low-nutrient media like distilled water. Biofilms can also form in condensate tanks in air-conditioning systems and in industrial heat exchangers. At present, bacteria in potable-water and plant-growth systems aboard the space shuttle (and previously on the Mir space station) are monitored by culture-plate counting, which entails an incubation period of 24 to 48 hours for each sample. At present, there are no commercially available instruments for continuous monitoring of biofilms in terrestrial or spaceborne settings.

Micheels, Ronald H.↗

NASA NTRS2004

Development of Biomorphic Flyers

Biomorphic flyers have recently been demonstrated that utilize the approach described earlier in "Bio-Inspired Engineering of Exploration Systems" (NPO-21142), NASA Tech Briefs, Vol. 27, No. 5 (May 2003), page 54, to distill the principles found in successful, nature-tested mechanisms of flight control. Two types of flyers are being built, corresponding to the imaging and shepherding flyers for a biomorphic mission described earlier in "Cooperative Lander- Surface/Aerial Microflyer Missions for Mars Exploration" (NPO-30286), NASA Tech Briefs, Vol. 28, No. 5 (May 2004), page 36. The common features of these two types of flyers are that both are delta-wing airplanes incorporating bio-inspired capabilities of control, navigation, and visual search for exploration. The delta-wing design is robust to approx.40 G axial load and offers ease of stowing and packaging. The prototype that we have built recently is shown in the figure. Such levels of miniaturization and autonomous navigation are essential to enable biomorphic microflyers (<1 kg) that can be deployed in large numbers for distributed measurements and exploration of difficult terrain while avoiding hazards. Individual bio-inspired sensors that will be incorporated in a biomorphic flyer have been demonstrated recently. These sensors include a robust, lightweight (~6 g), and low-power (~40 mW) horizon sensor for flight stabilization. It integrates successfully the principles of the dragonfly ocelli. The ocelli are small eyes on the dorsal and forward regions of the heads of many insects. The ocelli are distinct from the compound eyes that are most commonly associated with insect vision. In many insects, the ocelli are little more than single-point detectors of short-wavelength light and behavioral responses to ocelli stimuli are hard to observe. The notable exception is found in dragonflies, where flight control is notably degraded by any interference with the ocellar system. Our team has discovered recently that the ocelli are a dedicated horizon sensor, with substantial optical processing and multiple spectral sensitivity. To our knowledge, this is the world s first demonstrated use of a "biomorphic ocellus" as a flight-stabilization system. The advantage of the ocelli over a similarly sized system of rate gyroscopes is that both attitude control and rate damping can be realized in one device. A full inertial unit and significant processing would otherwise be required to achieve the same effect. As a prelude to full autonomy, substantial stability augmentation is provided to the pilot at very low cost in terms of space, power, and mass. The sensor is about 40 times lighter than a comparable inertial attitude reference system. Other significant features of the biomorphic flyer shown in the figure include its ability to fly at high angles of attack ~30 and a deep wing chord which allows scaling to small size and low Reynold s number situations. Furthermore, the placement of the propulsion system near the center of gravity allows continued control authority at low speeds. These attributes make such biomorphic flyers uniquely suited to planetary and terrestrial exploration where small size and autonomous airborne operation are required.

Thakoor, Sarita↗

NASA NTRS2006

Logistics Lessons Learned in NASA Space Flight

The Vision for Space Exploration sets out a number of goals, involving both strategic and tactical objectives. These include returning the Space Shuttle to flight, completing the International Space Station, and conducting human expeditions to the Moon by 2020. Each of these goals has profound logistics implications. In the consideration of these objectives,a need for a study on NASA logistics lessons learned was recognized. The study endeavors to identify both needs for space exploration and challenges in the development of past logistics architectures, as well as in the design of space systems. This study may also be appropriately applied as guidance in the development of an integrated logistics architecture for future human missions to the Moon and Mars. This report first summarizes current logistics practices for the Space Shuttle Program (SSP) and the International Space Station (ISS) and examines the practices of manifesting, stowage, inventory tracking, waste disposal, and return logistics. The key findings of this examination are that while the current practices do have many positive aspects, there are also several shortcomings. These shortcomings include a high-level of excess complexity, redundancy of information/lack of a common database, and a large human-in-the-loop component. Later sections of this report describe the methodology and results of our work to systematically gather logistics lessons learned from past and current human spaceflight programs as well as validating these lessons through a survey of the opinions of current space logisticians. To consider the perspectives on logistics lessons, we searched several sources within NASA, including organizations with direct and indirect connections with the system flow in mission planning. We utilized crew debriefs, the John Commonsense lessons repository for the JSC Mission Operations Directorate, and the Skylab Lessons Learned. Additionally, we searched the public version of the Lessons Learned Information System (LLIS) and verified that we received the same result using the internal version of LLIS for our logistics lesson searches. In conducting the research, information from multiple databases was consolidated into a single spreadsheet of 300 lessons learned. Keywords were applied for the purpose of sorting and evaluation. Once the lessons had been compiled, an analysis of the resulting data was performed, first sorting it by keyword, then finding duplication and root cause, and finally sorting by root cause. The data was then distilled into the top 7 lessons learned across programs, centers, and activities.

Evans, William A.↗