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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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NASA NTRS2003

Evaluation of Candidate Materials for a High-Temperature Stirling Convertor Heater Head

The Department of Energy (DOE) and NASA have identified Stirling Radioisotope Generators (SRG) as a candidate power system for use on long-duration, deep-space science missions and Mars rovers. One of the developments planned for an upgraded version of the current SRG design is to achieve higher efficiency by increasing the overall operating temperature of the system. Currently, the SRG operates with a heater head temperature of 650 C and is fabricated from the nickel base superalloy 718. This temperature is at the limit of Alloy 718's capability, and any planned increase in temperature will be contingent on identifying a more capable material from which to fabricate the heater head. To this end, an assessment of material candidates was performed assuming a range of heater head temperatures. The chosen alternative material candidates will be discussed, along with the development efforts needed to ensure that these materials can meet the demanding system requirements of long-duration operation in hostile environments.

Bowman, Randy↗

NASA NTRS2004

Reliability Assessment Approach for Stirling Convertors and Generators

Stirling power conversion is being considered for use in a Radioisotope Power System for deep-space science missions because it offers a multifold increase in the conversion efficiency of heat to electric power. Quantifying the reliability of a Radioisotope Power System that utilizes Stirling power conversion technology is important in developing and demonstrating the capability for long-term success. A description of the Stirling power convertor is provided, along with a discussion about some of the key components. Ongoing efforts to understand component life, design variables at the component and system levels, related sources, and the nature of uncertainties is discussed. The requirement for reliability also is discussed, and some of the critical areas of concern are identified. A section on the objectives of the performance model development and a computation of reliability is included to highlight the goals of this effort. Also, a viable physics-based reliability plan to model the design-level variable uncertainties at the component and system levels is outlined, and potential benefits are elucidated. The plan involves the interaction of different disciplines, maintaining the physical and probabilistic correlations at all the levels, and a verification process based on rational short-term tests. In addition, both top-down and bottom-up coherency were maintained to follow the physics-based design process and mission requirements. The outlined reliability assessment approach provides guidelines to improve the design and identifies governing variables to achieve high reliability in the Stirling Radioisotope Generator design.

Shah, Ashwin R.↗

NASA NTRS2002

Long-Term Creep of a Thin-Walled Inconel 718 Stirling Power-Convertor Heater Head Assessed

The Department of Energy and NASA have identified Stirling power convertors as candidate power supply systems for long-duration, deep-space science missions. A key element for qualifying the flight hardware is a long-term durability assessment for critical hot section components of the power convertor. One such critical component is the power convertor heater head. The heater head is a high-temperature pressure vessel that transfers heat to the working gas medium of the convertor, which is typically helium. An efficient heater head design is the result of balancing the divergent requirements of thin walls for increased heat transfer versus thick walls to lower the wall stresses and thus improve creep resistance and durability. In the current design, the heater head is fabricated from the Ni-base superalloy Inconel 718 (IN 718, Inco Alloys International, Inc., Huntington, WV). Although IN 718 is a mature alloy system (patented in 1962), there is little long-term (>50,000-hr) creep data available for thin-specimen geometries. Since thin-section properties tend to be inferior to thicker samples, it is necessary to generate creep data using specimens with the same geometry as the actual flight hardware. Therefore, one facet of the overall durability assessment program involves generating relatively short-term creep data using thin specimens at the design temperature of 649 C (1200 F).

Bowman, Randy R.↗

NASA NTRS2000

Radio Frequency (RF) Micro-Electromechanical Systems (MEMS) Switches for Space Communications

Micro-electromechanical systems (MEMS) is an emerging technology for radio frequency (RF) systems because it has the potential to dramatically decrease loss and improve efficiency. In this paper, we address the design and fabrication of novel MEMS switches being developed at NASA Glenn Research Center. Two types of switches are being developed: a microstrip series single pole single throw (SPST) switch and a coplanar waveguide (CPW) series SPST and single pole double throw (SPDT) switches. These are being fabricated as an integral part of 50 Ohm microstrip and CPW RF integrated circuits using microfabrication techniques. The construction of the switch relies on a cantilever beam that is partially supported by a dielectric post. The cantilever beam is electro-magnetically actuated. To decrease stiction, a Si3N4 thin film is deposited over the contact area. Thus, when the switch is closed, the ON-state insertion loss is governed by the parallel plate capacitance formed by the two contacts. The isolation in the OFF-state is governed by the parasitic capacitance when the cantilever is in the up position. RF MEMS switches have been demonstrated with 80% lower insertion loss than conventional solid state devices (GaAs Metal Semiconductor Field Effect Transistors (MESFETs) and Silicon PIN diodes) based switches. For example, a conventional GaAs five-bit phase shifter which is required for beam steering in a phased array antenna has approximately 7 dB of insertion loss at 26.5 GHz where as a comparable MEMS based phase shifter is expected to have only 2 dB of insertion loss. This translates into 56% lower power dissipation and therefore decreases the thermal load on the spacecraft and also reduces the power amplifier requirements. These benefits will enable NASA to build the next generation of deep space science crafts and micro/nano satellites.

Simons, Rainee N.↗

NASA NTRS2005

Candidate Materials Evaluated for a High-Temperature Stirling Convertor Heater Head

The Department of Energy and NASA have identified Stirling Radioisotope Generators (SRGs) as a candidate power system for use on long-duration, deep-space science missions and Mars rovers. One of the developments planned for an upgraded version of the current SRG design is to achieve higher efficiency by increasing the overall operating temperature of the system. Currently, the SRG operates with a heater head temperature of 650 C and is fabricated from the nickel-base superalloy 718. The current operating temperature is at the limit of alloy 718 s capability, and any planned increase in temperature will be contingent on identifying a more capable material from which to fabricate the heater head. To this end, personnel at the NASA Glenn Research Center are evaluating advanced materials for a high-temperature heater head to allow a higher convertor temperature ratio and, thus, increase the system efficiency. A generic list of properties that were used to screen the candidate materials follows: (1) creep, (2) fabricability, (3) helium gas containment, (4) long-term stability and compatibility, (5) ability to form a hermetical closeout seal, and (6) ductility and toughness.

Bowman, Randy R.↗

NASA NTRS2005

Reliability of the SRG110 Stirling Convertor Quantified

The NASA Glenn Research Center has been involved in the development of Stirling power-conversion technology and is currently providing technical support to the Department of Energy and Lockheed Martin, of Valley Forge, Pennsylvania, their system integration contractor, for the 110-W Stirling Radioisotope Generator (SRG110). Stirling radioisotope power-conversion technology is a potential candidate for future deep-space science and exploration missions. The SRG110 has a multifold increase in efficiency and would reduce the inventory of the radioisotope fuel by a factor of 4 in comparison to systems used to power past missions.

Shah, Ashwin R.↗

NASA NTRS2006

Stirling Convertor Fasteners Reliability Quantification

Onboard Radioisotope Power Systems (RPS) being developed for NASA s deep-space science and exploration missions require reliable operation for up to 14 years and beyond. Stirling power conversion is a candidate for use in an RPS because it offers a multifold increase in the conversion efficiency of heat to electric power and reduced inventory of radioactive material. Structural fasteners are responsible to maintain structural integrity of the Stirling power convertor, which is critical to ensure reliable performance during the entire mission. Design of fasteners involve variables related to the fabrication, manufacturing, behavior of fasteners and joining parts material, structural geometry of the joining components, size and spacing of fasteners, mission loads, boundary conditions, etc. These variables have inherent uncertainties, which need to be accounted for in the reliability assessment. This paper describes these uncertainties along with a methodology to quantify the reliability, and provides results of the analysis in terms of quantified reliability and sensitivity of Stirling power conversion reliability to the design variables. Quantification of the reliability includes both structural and functional aspects of the joining components. Based on the results, the paper also describes guidelines to improve the reliability and verification testing.

Shah, Ashwin R.↗

NASA NTRS2000

Advanced Ion Propulsion Systems for Affordable Deep-Space Missions

A key feature of future deep-space science missions will be the need for significantly greater on board propulsion capability.

ion propulsion SEP electric propulsion ion thruste↗

NASA NTRS2003

Validation and verification of deep-space missions

The growing technical complexity of and increased cost pressure on deep-space science missions poses challenges for the system engineering discipline of mission validation and verification. In the wake of several recent mission failures, the aerospace community is still searching for a stable middle ground between the highly-reliable yet cost-prohibitive approaches of the past and cheaper but excessively risky methods of project implementation.

system engineering validation verification↗

NASA NTRS2007

Performance of a Low-Power Cylindrical Hall Thruster

Recent mission studies have shown that a Hall thruster which operates at relatively constant thrust efficiency (45-55%) over a broad power range (300W - 3kW) is enabling for deep space science missions when compared with slate-of-the-art ion thrusters. While conventional (annular) Hall thrusters can operate at high thrust efficiency at kW power levels, it is difficult to construct one that operates over a broad power envelope down to 0 (100 W) while maintaining relatively high efficiency. In this note we report the measured performance (I(sub sp), thrust and efficiency) of a cylindrical Hall thruster operating at 0 (100 W) input power.

Polzin, Kurt A.↗

NASA NTRS2007

Recent Advances in Nuclear Powered Electric Propulsion for Space Exploration

Nuclear and radioisotope powered electric thrusters are being developed as primary in-space propulsion systems for potential future robotic and piloted space missions. Possible applications for high power nuclear electric propulsion include orbit raising and maneuvering of large space platforms, lunar and Mars cargo transport, asteroid rendezvous and sample return, and robotic and piloted planetary missions, while lower power radioisotope electric propulsion could significantly enhance or enable some future robotic deep space science missions. This paper provides an overview of recent U.S. high power electric thruster research programs, describing the operating principles, challenges, and status of each technology. Mission analysis is presented that compares the benefits and performance of each thruster type for high priority NASA missions. The status of space nuclear power systems for high power electric propulsion is presented. The paper concludes with a discussion of power and thruster development strategies for future radioisotope electric propulsion systems,

Cassady, R. Joseph↗

NASA NTRS2012

Advancement of a 30K W Solar Electric Propulsion System Capability for NASA Human and Robotic Exploration Missions

Solar Electric Propulsion has evolved into a demonstrated operational capability performing station keeping for geosynchronous satellites, enabling challenging deep-space science missions, and assisting in the transfer of satellites from an elliptical orbit Geostationary Transfer Orbit (GTO) to a Geostationary Earth Orbit (GEO). Advancing higher power SEP systems will enable numerous future applications for human, robotic, and commercial missions. These missions are enabled by either the increased performance of the SEP system or by the cost reductions when compared to conventional chemical propulsion systems. Higher power SEP systems that provide very high payload for robotic missions also trade favorably for the advancement of human exploration beyond low Earth orbit. Demonstrated reliable systems are required for human space flight and due to their successful present day widespread use and inherent high reliability, SEP systems have progressively become a viable entrant into these future human exploration architectures. NASA studies have identified a 30 kW-class SEP capability as the next appropriate evolutionary step, applicable to wide range of both human and robotic missions. This paper describes the planning options, mission applications, and technology investments for representative 30kW-class SEP mission concepts under consideration by NASA

Smith, Bryan K.↗

NASA NTRS2015

Radioisotope Power System Pool Concept

Advanced Radioisotope Power Systems (RPS) for NASA deep space science missions have historically used static thermoelectric-based designs because they are highly reliable, and their radioisotope heat sources can be passively cooled throughout the mission life cycle. Recently, a significant effort to develop a dynamic RPS, the Advanced Stirling Radioisotope Generator (ASRG), was conducted by NASA and the Department of Energy, because Stirling based designs offer energy conversion efficiencies four times higher than heritage thermoelectric designs; and the efficiency would proportionately reduce the amount of radioisotope fuel needed for the same power output. However, the long term reliability of a Stirling based design is a concern compared to thermoelectric designs, because for certain Stirling system architectures the radioisotope heat sources must be actively cooled via the dynamic operation of Stirling converters throughout the mission life cycle. To address this reliability concern, a new dynamic Stirling cycle RPS architecture is proposed called the RPS Pool Concept.

Power↗

NASA NTRS2013

Advanced Stirling Radioisotope Generator Life Certification Plan

An Advanced Stirling Radioisotope Generator (ASRG) power supply is being developed by the Department of Energy (DOE) in partnership with NASA for potential future deep space science missions. Unlike previous radioisotope power supplies for space exploration, such as the passive MMRTG used recently on the Mars Curiosity rover, the ASRG is an active dynamic power supply with moving Stirling engine mechanical components. Due to the long life requirement of 17 years and the dynamic nature of the Stirling engine, the ASRG project faced some unique challenges trying to establish full confidence that the power supply will function reliably over the mission life. These unique challenges resulted in the development of an overall life certification plan that emphasizes long-term Stirling engine test and inspection when analysis is not practical. The ASRG life certification plan developed is described.

Rusick, Jeffrey J.↗

NASA NTRS2013

Advanced Stirling Radioisotope Generator Life Certification Plan

Rusick, Jeffrey J.↗

NASA NTRS2010

MOS 2.0: The Next Generation in Mission Operations Systems

A Mission Operations System (MOS) or Ground System constitutes that portion of an overall space mission Enterprise that resides here on Earth. Over the past two decades, technological innovations in computing and software technologies have allowed an MOS to support ever more complex missions while consuming a decreasing fraction of Project development budgets. Despite (or perhaps, because of) such successes, it is routine to hear concerns about the cost of MOS development. At the same time, demand continues for Ground Systems which will plan more spacecraft activities with fewer commanding errors, provide scientists and engineers with more autonomous functionality, process and manage larger and more complex data more quickly, all while requiring fewer people to develop, deploy, operate and maintain them. One successful approach to such concerns over this period is a multimission approach, based on the reuse of portions (most often software) developed and used in previous missions. The Advanced Multi-Mission Operations System (AMMOS), developed for deep-space science missions, is one successful example of such an approach. Like many computing-intensive systems, it has grown up in a near-organic fashion from a relatively simple set of tools into a complexly interrelated set of capabilities. Such systems, like a city lacking any concept of urban planning, can and will grow in ways that are neither efficient nor particularly easy to sustain. To meet the growing demands and unyielding constraints placed on ground systems, a new approach is necessary. Under the aegis of a multi-year effort to revitalize the AMMOS's multimission operations capabilities, we are utilizing modern practices in systems architecting and model-based engineering to create the next step in Ground Systems: MOS 2.0. In this paper we outline our work (ongoing and planned) to architect and design a multimission MOS 2.0, describe our goals and measureable objectives, and discuss some of the benefits that this top-down, architectural approach holds for creating a more flexible and capable MOS for Missions while holding the line on cost.

ground systems↗

NASA NTRS2015

Comparison of Solar Electric and Chemical Propulsion Missions

Solar Electric Propulsion (SEP) offers fuel efficiency and mission robustness for spacecraft. The combination of solar power and electric propulsion engines is currently used for missions ranging from geostationary stationkeeping to deep space science because of these benefits. Both solar power and electric propulsion technologies have progressed to the point where higher electric power systems can be considered, making substantial cargo missions and potentially human missions viable. This paper evaluates and compares representative lunar, Mars, and Sun-Earth Langrangian point missions using SEP and chemical propulsion subsystems. The potential benefits and limitations are discussed along with technology gaps that need to be resolved for such missions to become possible. The connection to NASA's human architecture and technology development efforts will be discussed.

solar electric propulsion↗

NASA NTRS2017

NASA's Near Earth Asteroid Scout Mission

NASA is developing solar sail propulsion for a near-term Near Earth Asteroid (NEA) reconnaissance mission and laying the groundwork for their future use in deep space science and exploration missions. The NEA Scout mission, funded by NASA's Advanced Exploration Systems Program and managed by NASA MSFC, will use the sail as primary propulsion allowing it to survey and image one or more NEA's of interest for possible future human exploration. NEA Scout uses a 6U cubesat (to be provided by NASA's Jet Propulsion Laboratory), an 86 m2 solar sail and will weigh less than 14 kilograms. The solar sail for NEA Scout will be based on the technology developed and flown by the NASA NanoSail-D and The Planetary Society's Lightsail-A. Four ~7 m stainless steel booms wrapped on two spools (two overlapping booms per spool) will be motor deployed and pull the sail from its stowed volume. The sail material is an aluminized polyimide approximately 3 microns thick. NEA Scout will launch on the Space Launch System (SLS) first mission in 2018 and deploy from the SLS after the Orion spacecraft is separated from the SLS upper stage. The NEA Scout spacecraft will stabilize its orientation after ejection using an onboard cold-gas thruster system. The same system provides the vehicle Delta-V sufficient for a lunar flyby. After its first encounter with the moon, the 86 m2 sail will deploy, and the sail characterization phase will begin. A mechanical Active Mass Translation (AMT) system, combined with the remaining ACS propellant, will be used for sail momentum management. Once the system is checked out, the spacecraft will perform a series of lunar flybys until it achieves optimum departure trajectory to the target asteroid. The spacecraft will then begin its two year-long cruise. About one month before the asteroid flyby, NEA Scout will pause to search for the target and start its approach phase using a combination of radio tracking and optical navigation. The solar sail will provide continuous low thrust to enable a relatively slow flyby of the target asteroid under lighting conditions favorable to geological imaging. Once complete, NASA will have demonstrated the capability to fly low-cost, high Delta-V cubesats to perform interplanetary missions.

Johnson, Les↗