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Thermal Management Challenges and Technology Options for Lunar Regenerative Fuel Cells

Regenerative Fuel Cells (RFCs) enable lunar surface hardware, from pressurized rovers to surface habitats, to survive the lunar night by providing the required energy storage with a lower mass than state of the art battery systems. RFCs consist of fuel cell and electrolyzer electrochemical stack(s), a fluidic balance of plant, and electrical balance of plant. Fuel cells operate by converting the stored chemical energy of reactants into DC electrical power, heat, and water. When supplied DC power from an available external source, electrolyzers regenerate the reactants through electrolysis. The balance of plant is a critical part of the integrated system consisting of many individual components and provides fluid pressure management and conditioning, fluid storage, and thermal management. Component technology development is required to create an RFC system that will be capable of surviving the harsh lunar environment and maximize specific energy (W-hr/kg). One critical component requiring development includes a kW-scale high flux thermal switch. The primary requirement for the thermal switch is the ability to maintain low thermal resistance with the RFC heat rejection interface during the lunar day to maximize heat rejection while switching to a high thermal resistance during the lunar night such that the RFC can conserve as much thermal energy as possible. Different technology including freeze tolerant pumped loop, passive louvers, and variable conductance heat pipes were assessed as potential solutions. NASA is exploring development options through internal and external partnerships to develop this technology critical for a spaceflight RFC system.

Energy Storage↗

NASA NTRS2012

Quasi 1D Modeling of Mixed Compression Supersonic Inlets

The AeroServoElasticity task under the NASA Supersonics Project is developing dynamic models of the propulsion system and the vehicle in order to conduct research for integrated vehicle dynamic performance. As part of this effort, a nonlinear quasi 1-dimensional model of the 2-dimensional bifurcated mixed compression supersonic inlet is being developed. The model utilizes computational fluid dynamics for both the supersonic and subsonic diffusers. The oblique shocks are modeled utilizing compressible flow equations. This model also implements variable geometry required to control the normal shock position. The model is flexible and can also be utilized to simulate other mixed compression supersonic inlet designs. The model was validated both in time and in the frequency domain against the legacy LArge Perturbation INlet code, which has been previously verified using test data. This legacy code written in FORTRAN is quite extensive and complex in terms of the amount of software and number of subroutines. Further, the legacy code is not suitable for closed loop feedback controls design, and the simulation environment is not amenable to systems integration. Therefore, a solution is to develop an innovative, more simplified, mixed compression inlet model with the same steady state and dynamic performance as the legacy code that also can be used for controls design. The new nonlinear dynamic model is implemented in MATLAB Simulink. This environment allows easier development of linear models for controls design for shock positioning. The new model is also well suited for integration with a propulsion system model to study inlet/propulsion system performance, and integration with an aero-servo-elastic system model to study integrated vehicle ride quality, vehicle stability, and efficiency.

Kopasakis, George↗

DOE OSTI2024

Evaluation of Lost Circulation Material Sealing for Geothermal Drilling

Lost circulation is a pervasive problem in geothermal wells that can create prohibitive costs during drilling. The main issue with treatment is that the mechanism of plug formation is poorly understood. Here we applied two experimental approaches to characterize the clogging effectiveness of different materials. Fracture flow tests with different geometries were conducted with various individual materials and mixtures at relevant conditions. A high-temperature flow loop system was also developed to inject single- and mixed-material plugs into a gravel pack with a non-uniform geometry to compare with the fracture tests. The fracture tests revealed that single materials tended to form no plug or an unstable plug, while mixtures of materials were uniformly better at sealing fractures. Gravel pack tests at high temperatures show most of the materials are intact but degraded. The fibrous materials can create partial or unstable plugs in the gravel pack, but mixed-material plugs are far more effective at clogging. Both test types suggest that (1) mixed materials are more effective at blocking fluid flow and (2) fibrous materials seal fracture openings better, while granular materials seal inside fractures or pore throats better. Further research is needed to study the long-term stability of different plug configurations.

clogging tests↗

NASA NTRS2013

FRET-Aptamer Assays for Bone Marker Assessment, C-Telopeptide, Creatinine, and Vitamin D

Astronauts lose 1.0 to 1.5% of their bone mass per month on long-duration spaceflights. NASA wishes to monitor the bone loss onboard spacecraft to develop nutritional and exercise countermeasures, and make adjustments during long space missions. On Earth, the same technology could be used to monitor osteoporosis and its therapy. Aptamers bind to targets against which they are developed, much like antibodies. However, aptamers do not require animal hosts or cell culture and are therefore easier, faster, and less expensive to produce. In addition, aptamers sometimes exhibit greater affinity and specificity vs. comparable antibodies. In this work, fluorescent dyes and quenchers were added to the aptamers to enable pushbutton, one-step, bind-and-detect fluorescence resonance energy transfer (FRET) assays or tests that can be freeze-dried, rehydrated with body fluids, and used to quantitate bone loss of vitamin D levels with a handheld fluorometer in the spacecraft environment. This work generated specific, rapid, one-step FRET assays for the bone loss marker C-telopeptide (CTx) when extracted from urine, creatinine from urine, and vitamin D congeners in diluted serum. The assays were quantified in nanograms/mL using a handheld fluorometer connected to a laptop computer to convert the raw fluorescence values into concentrations of each analyte according to linear standard curves. DNA aptamers were selected and amplified for several rounds against a 26- amino acid form of CTx, creatinine, and vitamin D. The commonalities between loop structures were studied, and several common loop structures were converted into aptamer beacons with a fluorophore and quencher on each end. In theory, when the aptamer beacon binds its cognate target (CTx bone peptide, creatinine, or vitamin D), it is forced open and no longer quenched, so it gives off fluorescent light (when excited) in proportion to the amount of target present in a sample. This proportional increase in fluorescence is called a "lights on" FRET response. The vitamin D aptamer beacon gives a "lights off" or inversely proportional fluorescence response to the amount of vitamin D present in diluted serum. These FRET-aptamer assays are rapid (<30 minutes), sensitive (low ng/mL detection limits), and quite easy to carry out (add sample, mix, and detect in the handheld reader). Benefits include the speed of the assays as well as the small amount of space taken up by the handheld reader and cuvette assays. The aptamer DNA sequences represent novel additional features of the existing (patent-pending) FRET-aptamer assay platform.

Bruno, John G.↗

NASA NTRS1999

Thermal Analysis of Magnetically-Coupled Pump for Cryogenic Applications

Magnetically-coupled pump is under evaluation at Kennedy Space Center for possible cryogenic applications. A major concern is the impact of low temperature fluid flows on the pump performance. As a first step toward addressing this and related issues, a computational fluid dynamics and heat transfer tool has been adopted in a pump geometry. The computational tool includes (i) a commercial grid generator to handle multiple grid blocks and complicated geometric definitions, and (ii) an in-house computational fluid dynamics and heat transfer software developed in the Principal Investigator's group at the University of Florida. Both pure-conduction and combined convection-conduction computations have been conducted. A pure-conduction analysis gives insufficient information about the overall thermal distribution. Combined convection-conduction analysis indicates the significant influence of the coolant over the entire flow path. Since 2-D simulation is of limited help, future work on full 3-D modeling of the pump using multi-materials is needed. A comprehensive and accurate model can be developed to take into account the effect of multi-phase flow in the cooling flow loop, and the magnetic interactions.

Senocak, Inanc↗

NASA NTRS1991

Nuclear light bulb

The nuclear light bulb engine is a closed cycle concept. The nuclear light bulb concept provides containment by keeping the nuclear fuel fluid mechanically suspended in a cylindrical geometry. Thermal heat passes through an internally cooled, fused-silica, transparent wall and heats hydrogen propellant. The seeded hydrogen propellant absorbs radiant energy and is expanded through a nozzle. Internal moderation was used in the configuration which resulted in a reduced critical density requirement. This result was supported by criticality experiments. A reference engine was designed that had seven cells and was sized to fit in what was then predicted to be the shuttle bay mass and volume limitations. There were studies done of nozzle throat cooling schemes to remove the radiant heat. Elements of the nuclear light bulb program included closed loop critical assembly tests done at Los Alamos with UF6 confined by argon buffer gas. It was shown that the fuel region could be seeded with constituents that would block UV radiation from the uranium plasma. A combination of calculations and experiments showed that internal moderation produced a critical mass reduction. Other aspects of the research are presented.

Latham, Tom↗

NASA NTRS1988

Effects of eletron heating on the current driven electrostatic ion cyclotron instability and plasma transport processes along auroral field lines

Fluid simulations of the plasma along auroral field lines in the return current region have been performed. It is shown that the onset of electrostatic ion cyclotron (EIC) related anomalous resistivity and the consequent heating of electrons leads to a transverse ion temperature that is much higher than that produced by the current driven EIC instability (CDICI) alone. Two processes are presented for the enhancement of ion heating by anomalous resistivity. The anomalous resistivity associated with the turbulence is limited by electron heating, so that CDICI saturates at transverse temperature that is substantially higher than in the absence of resistivity. It is suggested that this process demonstrates a positive feedback loop in the interaction between CDICI, anomalous resistivity, and parallel large-scale dynamics in the topside ionosphere.

Ganguli, Supriya B.↗

NASA NTRS2010

Microbial Challenge Testing of Single Liquid Cathode Feed Water Electrolysis Cells for the International Space Station (ISS) Oxygen Generator Assembly (OGA)

The International Space Station (ISS) Oxygen Generator Assembly (OGA) operational performance may be adversely impacted by microbiological growth and biofilm formation over the electrolysis cell membranes. Biofilms could hinder the transport of water from the bulk fluid stream to the membranes and increase the cell resistance resulting in higher cell voltages and a shorter cell life. A microbial challenge test was performed on duplicate single liquid cathode feed electrolyzer cells to evaluate operational performance with increasing levels of a mixture of five bacteria isolated from ISS and Space Shuttle potable water systems. Baseline performance of the single water electrolysis cells was determined for approximately one month with deionized water. Monthly performance was also determined following each inoculation of the feed tank with 100, 1000, 10,000 and 100,000 cells/ml of the mixed suspension of test bacteria. Water samples from the feed tank and recirculating water loops for each cell were periodically analyzed for enumeration and speciation of bacteria and total organic carbon. While initially a concern, this test program has demonstrated that the performance of the electrolysis cell is not adversely impacted by feed water containing the five species of bacteria tested at a concentration measured as high as 1,000,000 colony forming units (CFU)/ml. This paper presents the methodologies used in the conduct of this test program along with the performance test results at each level of bacteria concentration.

Diderich, Greg S.↗

NASA NTRS2001

System Accommodation of Propylene Loop Heat Pipes For The Geoscience Laser Altimeter System (GLAS) Instrument

Loop Heat Pipes (LHP) are used for precise temperature control for NASA Goddard Space Flight Center's Geoscience Laser Altimeter System (GLAS) Instrument in a widely varying LEO thermal environment. Two propylene LHPs are utilized to provide separate thermal control for the Nd:YAG Lasers and the remaining avionics/detector components suite. Despite a rigorous engineering development and test plan to demonstrate the performance in the restrictive GLAS design, the flight units failed initial thermal vacuum acceptance testing at GSFC. Subsequent investigation revealed that compromises in the mechanical packaging of these systems resulted in inadequate charge levels for a concentric wick LHP. The redesign effort included larger compensation chambers that provide more fluid to the wick for start-up scenarios and highlighted the need to fully understand the limitations and accommodation requirements of new technologies in a system design application. Once again, seemingly minor departures from heritage configurations and limited resources led to performance and operational issues. This paper provides details into the GLAS LHP engineering development program and acceptance testing of the flight units, including the redesign effort.

Grob, Eric W.↗

NASA NTRS1984

Magnetic reconnection and magnetic activity

A large-scale magnetic field extending through a highly conducting tenuous fluid may become distorted on a small scale as a consequence of slow small-scale shuffling of the magnetic lines of force at the boundaries of the tenuous fluid. Any slow wrapping and winding introduced at the boundaries is distributed along the field (at the Alfven speed). It is a curious and little-known fact that such wrapping and winding possesses no static equilibrium (except for a set of solutions of extreme symmetry). The result is neutral-point reconnection of the strains in the field, rapidly dissipating the wrapping and winding. It is suggested that this is the principal cause of the extreme heating that produces the active corona of the sun and other stars. The shuffling of the footpoints of the magnetic field in the photospheric turbulence introduces small-scale wrapping and twisting into the coronal loops. The work done by the turbulence in twisting the fields is dissipated within a matter 10-20 hours by neutral-point reconnection, introducing heat into the corona at a rate of about 10 Mergs/sq cm sec for photospheric turbulence of 0.5 km/sec. It is suggested that this is the basic cause of the X-ray corona.

Parker, E. N.↗

NASA NTRS2002

Inducer Hydrodynamic Load Measurement Devices

Marshall Space Flight Center (MSFC) has demonstrated two measurement devices for sensing and resolving the hydrodynamic loads on fluid machinery. The first - a derivative of the six component wind tunnel balance - senses the forces and moments on the rotating device through a weakened shaft section instrumented with a series of strain gauges. This "rotating balance" was designed to directly measure the steady and unsteady hydrodynamic loads on an inducer, thereby defining both the amplitude and frequency content associated with operating in various cavitation modes. The second device - a high frequency response pressure transducer surface mounted on a rotating component - was merely an extension of existing technology for application in water. MSFC has recently completed experimental evaluations of both the rotating balance and surface-mount transducers in a water test loop. The measurement bandwidth of the rotating balance was severely limited by the relative flexibility of the device itself, resulting in an unexpectedly low structural bending mode and invalidating the higher frequency response data. Despite these limitations, measurements confirmed that the integrated loads on the four-bladed inducer respond to both cavitation intensity and cavitation phenomena. Likewise, the surface-mount pressure transducers were subjected to a range of temperatures and flow conditions in a non-rotating environment to record bias shifts and transfer functions between the transducers and a reference device. The pressure transducer static performance was within manufacturer's specifications and dynamic response accurately followed that of the reference.

Skelley, Stephen E.↗

NASA NTRS2002

Inducer Hydrodynamic Load Measurement Devices

Marshall Space Flight Center (MSFC) has demonstrated two measurement devices for sensing and resolving the hydrodynamic loads on fluid machinery. The first - a derivative of the six-component wind tunnel balance - senses the forces and moments on the rotating device through a weakened shaft section instrumented with a series of strain gauges. This rotating balance was designed to directly measure the steady and unsteady hydrodynamic loads on an inducer, thereby defining both the amplitude and frequency content associated with operating in various cavitation modes. The second device - a high frequency response pressure transducer surface mounted on a rotating component - was merely an extension of existing technology for application in water. MSFC has recently completed experimental evaluations of both the rotating balance and surface-mount transducers in a water test loop. The measurement bandwidth of the rotating balance was severely limited by the relative flexibility of the device itself, resulting in an unexpectedly low structural bending mode and invalidating the higher-frequency response data. Despite these limitations, measurements confirmed that the integrated loads on the four-bladed inducer respond to both cavitation intensity and cavitation phenomena. Likewise, the surface-mount pressure transducers were subjected to a range of temperatures and flow conditions in a non-rotating environment to record bias shifts and transfer functions between the transducers and a reference device. The pressure transducer static performance was within manufacturer's specifications and dynamic response accurately followed that of the reference.

Skelley, Stephen E.↗

NASA NTRS2006

Evaluation of an Integrated Gas-Cooled Reactor Simulator and Brayton Turbine-Generator

A closed-loop brayton cycle, powered by a fission reactor, offers an attractive option for generating both planetary and in-space electric power. Non-nuclear testing of this type of system provides the opportunity to safely work out integration and system control challenges for a modest investment. Recognizing this potential, a team at Marshall Space Flight Center has evaluated the viability of integrating and testing an existing gas-cooled reactor simulator and a modified commercially available, off-the-shelf, brayton turbine-generator. Since these two systems were developed independently of one another, this evaluation had to determine if they could operate together at acceptable power levels, temperatures, and pressures. Thermal, fluid, and structural analyses show that this combined system can operate at acceptable power levels and temperatures. In addition, pressure drops across the reactor simulator, although higher than desired, are also viewed as acceptable. Three potential working fluids for the system were evaluated: N2, He/Ar, and He/Xe. Other potential issues, such as electrical breakdown in the generator and the operation of the brayton foil bearings using various gas mixtures, were also investigated.

Hissam, David Andy↗

NASA NTRS2009

System Modeling of Metabolic Heat Regenerated Temperature Swing Adsorption (MTSA) Subassembly for Prototype Design

This paper describes modeling methods for the three core components of a Metabolic heat regenerated Temperature Swing Adsorption (MTSA) subassembly: the sorbent bed, a sublimation (cooling) heat exchanger (SHX), and a condensing icing (warming) heat exchanger (CIHX). The primary function of the MTSA, removing carbon dioxide from a ventilation loop, is performed via the sorbent bed. The CIHX is used to heat the sorbent bed for desorption and to remove moisture from the ventilation loop while the SHX is alternately employed to cool the sorbent bed via sublimation of a spray of water at low pressure to prepare the reconditioned bed for the next cycle. This paper describes a system level model of the MTSA as developed in Thermal Desktop and SINDA/FLUINT including assumptions on geometry and physical phenomena, modeling methodology and relevant pa ra mete rizatio ns. Several areas of particular modeling interest are discussed. In the sorbent bed, capture of the translating CO2 saturation front and associated local energy and mass balance in both adsorbing and desorbing modes is covered. The CIHX poses particular challenges for modeling in SINDA/FLUINT as accounting for solids states in fluid submodels are not a native capability. Methods for capturing phase change and latent heat of ice as well as the transport properties across a layer of low density accreted frost are developed. This extended modeling capacity is applicable to temperatures greater than 258 K. To extend applicability to the minimum device temperature of 235 K, a method for a mapped transformation of temperatures from below the limit temperatures to some value above is given along with descriptions for associated material property transformations and the resulting impacts to total heat and mass transfer. Similar considerations are shown for the SHX along with assumptions for flow mechanics and resulting model methods for sublimation in a flow.

Bower, Chad↗

NASA NTRS2011

Microbial Challenge Testing of Single Liquid Cathode Feed Water Electrolysis Cells for the International Space Station (ISS) Oxygen Generator Assembly (OGA)

The International Space Station (ISS) Oxygen Generator Assembly (OGA) operational performance may be adversely impacted by microbiological growth and biofilm formation over the electrolysis cell membranes. Biofilms could hinder the transport of water from the bulk fluid stream to the membranes and increase the cell concentration overpotential resulting in higher cell voltages and a shorter cell life. A microbial challenge test was performed on duplicate single liquid-cathode feed water electrolysis cells to evaluate operational performance with increasing levels of a mixture of five bacteria isolated from ISS and Space Shuttle potable water systems. Baseline performance of the single water electrolysis cells was determined for approximately one month with deionized water. Monthly performance was also determined following each inoculation of the feed tank with 100, 1000, 10,000 and 100,000 cells/ml of the mixed suspension of test bacteria. Water samples from the feed tank and recirculating water loops for each cell were periodically analyzed for enumeration and speciation of bacteria and total organic carbon. While initially a concern, this test program has demonstrated that the performance of the electrolysis cell is not adversely impacted by feed water containing the five species of bacteria tested at a concentration measured as high as 1,000,000 colony forming units (CFU)/ml. This paper presents the methodologies used in the conduct of this test program along with the performance test results at each level of bacteria concentration.

Roy, Robert J.↗

NASA NTRS1982

Solar transition region response to variations in the heating rate

The response of a numerical model for the upper chromosphere, transition region, and corona to variations in the energy input has been examined. The numerical model solves the set of one-dimensional two-fluid hydrodynamic equations in a simple vertical magnetic flux tube. The atmosphere responds to both the increase and decrease in energy deposition by smoothly readjusting the temperature gradient and the amount of material in the region of peak radiating efficiency to radiate away energy being deposited. At no time during this readjustment is a departure from a thin laminar transition region structure seen. In addition, a time-dependent description of the nonequilibrium ionization of all of the ionization stages of oxygen has been included. This calculation is coupled with the self-consistent calculations of the dynamical variables. It is found that the nonequilibrium ionization balance calculations for both heating and cooling small loops in the quiet sun predict relative ionic abundances which differ substantially from those which would be predicted by an equilibrium calculation

Mariska, J. T.↗

NASA NTRS2007

Loss-of-Control-Inhibitor Systems for Aircraft

Systems to provide improved tactile feedback to aircraft pilots are being developed to help the pilots maintain harmony between their control actions and the positions of aircraft control surfaces, thereby helping to prevent loss of control. A system of this type, denoted a loss-of-control-inhibitor system (LOCIS) can be implemented as a relatively simple addition to almost any pre-existing flight-control system. The LOCIS concept offers at least a partial solution to the problem of (1) keeping a pilot aware of the state of the control system and the aircraft and (2) maintaining sufficient control under conditions that, as described below, have been known to lead to loss of control. Current commercial aircraft exhibit uneven responses of primary flight-control surfaces to aggressive pilot control commands, leading to deterioration of pilots ability to control their aircraft. In severe cases, this phenomenon can result in loss of control and consequent loss of aircraft. For an older aircraft equipped with a purely mechanical control system, the loss of harmony between a pilot s command action and the control- surface response can be attributed to compliance in the control system (caused, for example, by stretching of control cables, flexing of push rods, or servo-valve distortion). In a newer aircraft equipped with a fly-by-wire control system, the major contributions to loss of harmony between the pilot and the control surfaces are delays attributable to computer cycle time, control shaping, filtering, aliasing, servo-valve distortion, and actuator rate limiting. In addition, a fly-by-wire control system provides no tactile feedback that would enable the pilot to sense such features of the control state as surface flutter, surface jam, position limiting, actuator rate limiting, and control limiting imposed by the aircraft operational envelope. Hence, for example, when a pilot is involved in aggressive closed-loop maneuvering, as when encountering a wake-vortex upset on final landing approach, the control-surface delay can lead to loss of control. Aggressive piloting can be triggered and exacerbated by control-system anomalies, which the pilot cannot diagnose because of the lack of symptoms caused by the absence of feedback through the controls. The purpose served by a LOCIS is to counteract these adverse effects by providing real-time feedback that notifies the pilot that the aircraft is tending to lag the pilot s commands. A LOCIS (see figure) includes cockpit control input-position sensors, control-surface output-position sensors, variable dampers (for example, shock absorbers containing magneto-rheological fluids such that the damping forces can be varied within times of the order of milliseconds by varying applied magnetic fields) attached to the cockpit control levers, electromagnet coils to apply the magnetic fields, and feedback control circuits to drive the electromagnet coils. The feedback control gains are chosen so that the current applied to each electromagnet coil results in a damping force that increases in a suitable nonlinear manner (e.g., exponentially) with the difference between the actual and commanded positions of the affected control surface. The increasing damping force both alerts the pilot to the onset of a potentially dangerous situation and resists the pilot s effort to command a control surface to change position at an excessive rate

AHarrah, Ralph C.↗

NASA NTRS2004

TopMaker: Technique Developed for Automatic Multiblock Topology Generation Using the Medial Axis

The TopMaker technique was developed in an effort to reduce the time required for grid generation in complex numerical studies. Topology generation accounts for much of the man-hours required for structured multiblock grids. With regard to structured multiblock grids, topology refers to how the blocks are arranged and connected. A two-dimensional multiblock topology generation technique has been developed at the NASA Glenn Research Center. Very general configurations can be addressed by the technique. A configuration is defined by a collection of non-intersecting closed curves, which will be referred to as loops. More than a single loop implies that holes exist in the domain, which poses no problem. This technique requires only the medial vertices and the touch points that define each vertex. From the information about the medial vertices, the connectivity between medial vertices is generated. The physical shape of the medial edge is not required. By applying a few simple rules to each medial edge, a multiblock topology can be generated without user intervention. The resulting topologies contain only the level of complexity dictated by the configurations. Grid lines remain attached to the boundary except at sharp concave turns, where a change in index family is introduced as would be desired. Keeping grid lines attached to the boundary is especially important in computational fluid dynamics, where highly clustered grids are used near no-slip boundaries. This technique is simple and robust and can easily be incorporated into the overall grid-generation process.

Rigby, David L.↗