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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 NTRS2009

Simplified Ion Thruster Xenon Feed System for NASA Science Missions

The successful implementation of ion thruster technology on the Deep Space 1 technology demonstration mission paved the way for its first use on the Dawn science mission, which launched in September 2007. Both Deep Space 1 and Dawn used a "bang-bang" xenon feed system which has proven to be highly successful. This type of feed system, however, is complex with many parts and requires a significant amount of engineering work for architecture changes. A simplified feed system, with fewer parts and less engineering work for architecture changes, is desirable to reduce the feed system cost to future missions. An attractive new path for ion thruster feed systems is based on new components developed by industry in support of commercial applications of electric propulsion systems. For example, since the launch of Deep Space 1 tens of mechanical xenon pressure regulators have successfully flown on commercial spacecraft using electric propulsion. In addition, active proportional flow controllers have flown on the Hall-thruster-equipped Tacsat-2, are flying on the ion thruster GOCE mission, and will fly next year on the Advanced EHF spacecraft. This present paper briefly reviews the Dawn xenon feed system and those implemented on other xenon electric propulsion flight missions. A simplified feed system architecture is presented that is based on assembling flight-qualified components in a manner that will reduce non-recurring engineering associated with propulsion system architecture changes, and is compared to the NASA Dawn standard. The simplified feed system includes, compared to Dawn, passive high-pressure regulation, a reduced part count, reduced complexity due to cross-strapping, and reduced non-recurring engineering work required for feed system changes. A demonstration feed system was assembled using flight-like components and used to operate a laboratory NSTAR-class ion engine. Feed system components integrated into a single-string architecture successfully operated the engine over the entire NSTAR throttle range over a series of tests. Flow rates were very stable with variations of at most 0.2%, and transition times between throttle levels were typically 90 seconds or less with a maximum of 200 seconds, both significant improvements over the Dawn bang-bang feed system.

Snyder, John Steven↗

NASA NTRS2010

Controlling Precision Stepper Motors in Flight Using (Almost) No Parts

This concept allows control of high-performance stepper motors with minimal parts count and minimal flight software complexity. Although it uses a small number of common flight-qualified parts and simple control algorithms, it is capable enough to meet demanding system requirements. Its programmable nature makes it trivial to implement changes to control algorithms both during integration & test and in flight. Enhancements such as microstepping, half stepping, back-emf compensation, and jitter reduction can be tailored to the requirements of a large variety of stepper motor based applications including filter wheels, focus mechanisms, antenna tracking subsystems, pointing and mobility. The hardware design (using an H-bridge motor controller IC) was adapted from JPL's MER mission, still operating on Mars. This concept has been fully developed and incorporated into the MCS instrument on MRO, currently operating in Mars orbit. It has been incorporated into the filter wheel mechanism and linear stage (focus) mechanism for the AMT instrument. On MCS/MRO, two of these circuits control the elevation and azimuth of the MCS telescope/radiometer assembly, allowing the instrument to continuously monitor the limb of the Martian atmosphere. Implementation on MCS/MRO resulted in a 4:1 reduction in the volume and mass required for the motor driver electronics (100:25 square inches of PCB space), producing a very compact instrument. In fact, all of the electronics for the MCS instrument are packaged within the movable instrument structure. It also saved approximately 3 Watts of power. Most importantly, the design enabled MCS to meet very its stringent maximum allowable torque disturbance requirements.

Randall, David↗

NASA NTRS2015

Evolvable Cryogenics (ECRYO) Pressure Transducer Calibration Test

This paper provides a summary of the findings of recent activities conducted by Marshall Space Flight Center's (MSFC) In-Space Propulsion Branch and MSFC's Metrology and Calibration Lab to assess the performance of current "state of the art" pressure transducers for use in long duration storage and transfer of cryogenic propellants. A brief historical narrative in this paper describes the Evolvable Cryogenics program and the relevance of these activities to the program. This paper also provides a review of three separate test activities performed throughout this effort, including: (1) the calibration of several pressure transducer designs in a liquid nitrogen cryogenic environmental chamber, (2) the calibration of a pressure transducer in a liquid helium Dewar, and (3) the calibration of several pressure transducers at temperatures ranging from 20 to 70 degrees Kelvin (K) using a "cryostat" environmental chamber. These three separate test activities allowed for study of the sensors along a temperature range from 4 to 300 K. The combined data shows that both the slope and intercept of the sensor's calibration curve vary as a function of temperature. This homogeneous function is contrary to the linearly decreasing relationship assumed at the start of this investigation. Consequently, the data demonstrates the need for lookup tables to change the slope and intercept used by any data acquisition system. This ultimately would allow for more accurate pressure measurements at the desired temperature range. This paper concludes with a review of a request for information (RFI) survey conducted amongst different suppliers to determine the availability of current "state of the art" flight-qualified pressure transducers. The survey identifies requirements that are most difficult for the suppliers to meet, most notably the capability to validate the sensor's performance at temperatures below 70 K.

Diaz, Carlos E., Jr.↗

NASA NTRS2011

Performance of the QWIP Focal Plane Arrays for NASA's Landsat Data Continuity Mission

The focal plane assembly for the Thermal Infrared Sensor (TIRS) instrument on NASA's Landsat Data Continuity Mission (LDCM) consists of three 512 x 640 GaAs Quantum Well Infrared Photodetector (QWIP) arrays. The three arrays are precisely mounted and aligned on a silicon carrier substrate to provide a continuous viewing swath of 1850 pixels in two spectral bands defined by filters placed in close proximity to the detector surfaces. The QWIP arrays are hybridized to Indigo ISC9803 readout integrated circuits (ROICs). QWIP arrays were evaluated from four laboratories; QmagiQ, (Nashua, NH), Army Research Laboratory, (Adelphi, MD}, NASA/ Goddard Space Flight Center, (Greenbelt, MD) and Thales, (Palaiseau, France). All were found to be suitable. The final discriminating parameter was the spectral uniformity of individual pixels relative to each other. The performance of the QWIP arrays and the fully assembled, NASA flight-qualified, focal plane assembly will be reviewed. An overview of the focal plane assembly including the construction and test requirements of the focal plane will also be described.

Jhabvala, M.↗

NASA NTRS2014

Advancing Technologies for Climate Observation

Climate research needs Accurate global cloud ice measurements Cloud ice properties are fundamental controlling variables of radiative transfer and precipitation Cost-effective, sensitive instruments for diurnal and wide-swath coverage Mature technology for space remote sensing IceCube objectivesDevelop and validate a flight-qualified 883 GHz receiver for future use in ice cloud radiometer missions Raise TRL (57) of 883 GHz receiver technology Reduce instrument cost and risk by developing path to space for COTS sub-mm-wave receiver systems Enable remote sensing of global cloud ice with advanced technologies and techniques

radiative transfer↗

NASA NTRS2018

Performance of the QWIP Focal Plane Array for NASA's Landsat 9 Mission

The flight focal plane array (FPA) for the Thermal Infrared Sensor 2 (TIRS-2) instrument, to be flown on Landsat 9, was built and characterized at NASA Goddard Space Flight Center (GSFC). The FPA was assembled using GaAs quantum well infrared photodetector (QWIP) arrays from the same lot as the TIRS instrument on Landsat 8. Each QWIP array is hybridized to an Indigo ISC9803 readout integrated circuit (ROIC) with 640 x 512, 25µm by 25µm pixels. Each QWIP hybrid was tested at the NASA/GSFC Detector Characterization Laboratory (DCL) as a single sensor chip assembly (SCA). The best SCAs in terms of performance were then built up into an FPA consisting of three SCAs, required to provide the necessary 15-degree field of view of the instrument. The FPA was tested to determine if project requirements were being met as a fully assembled unit. The performance of the QWIP SCAs and the fully assembled, NASA flight-qualified FPA will be reviewed.

Quantum well infrared photodiode↗

NASA NTRS2016

Deep Space NanoSats - Positioned for Exponential Growth

We are poised at the beginning of a new era in solar system exploration, in which cubesats and nanosats can potentially play a big role. In 2012 a small group of like-minded enthusiasts at JPL predicted exponential growth in deep space cubesats with at least 10 exploring our solar system by 2020, and a 100 by 2030. Since then, JPL has built and flight-qualified the two INSPIRE spacecraft as pathfinders for future deep space cubesat missions, and the two MARCO spacecraft were assembled and tested in time to make the initial Insight launch opportunity in 2016 – now under consideration for the next available window. We have ongoing studies for lunar exploration and asteroid rendezvous missions, a Venus atmosphere sampler, and other concepts have been proposed to NASA. The Europa mission has 10 academic institutes under contract to study cubesats that would ride along with the main spacecraft to enable it to get closer to the surface of Jupiter’s most intriguing moon. Last year, ESA announced that its AIM asteroid probe will carry a small number of cubesats, when it launches in 2020. In the commercial world, Deep Space Industries are planning to host multiple cubesats in a mission to a Near Earth Asteroid. The prospects for near-term growth look reasonably healthy. This paper will provide an overview of deep space and LEO cubesat developments at JPL, and discuss the foundation they will provide for the growing community of interplanetary cubesat pioneers over the coming decade and a half.

Freeman, Anthony↗

NASA NTRSDate not supplied

The NEXT-C Power Processing Unit: Lessons Learned from the Design, Build, and Test of the NEXT-C PPU for APL's DART Mission

NASA’s Double Asteroid Redirection Test (DART) will be the first-ever planetary defense mission to demonstrate asteroid deflection using kinetic impactor technology. The DART spacecraft will utilize the NASA Evolutionary Xenon Thruster (NEXT), which is a successor to the NSTAR ion propulsion system that successfully propelled NASA’s Deep Space 1 and Dawn spacecraft. In 2015, NASA partnered with Aerojet Rocketdyne and ZIN Technologies on the NEXT-Commercial (NEXT-C) effort to manufacture a Flight-Qualified (TRL 8) power processing unit (PPU). The NEXT-C PPU was based on the heritage gridded ion thruster PPU from NSTAR and NEXT, but with significant improvements in performance and manufacturability. The design goals of the NEXT-C PPU were to achieve the technical performance goals of the PPU in size, mass, and efficiency over a wide range of input voltage and output power. This paper discusses the lessons learned from the design, build, and test of the NEXT-C PPU, and how challenges were overcome to deliver a Flight PPU.

NEXT-C↗

NASA NTRSDate not supplied

The NEXT-C Power Processing Unit: Lessons Learned from the Design, Build, and Test of the NEXT-C PPU for APL's DART Mission

NEXT-C↗

NASA NTRS2021

Extended Stroke and Miniaturized Reverse-Operation DTE Thermal Switches

This paper describes two advanced thermal switches under development that are offshoots of the recently flight-qualified 2500:1 reverse-operation differential thermal expansion (DTE) thermal switch (ROD-TSW). The first is the extended stroke ROD-TSW (ES-ROD-TSW) while the second is the miniaturized ROD-TSW (mini-ROD-TSW). Each employs multiple diametrically nested DTE stages in contrast to the single-stage ROD-TSW. The ES-ROD-TSW employs two stages and a negative CTE material known as Allvar and its main purpose is to extend its stroke for use in non-vacuum planetary environments. The mini-ROD-TSW employs four stages to miniaturize its size for use in compact lunar instruments and rovers. The ES-ROD-TSW was TVAC tested at JPL and its ON/OFF ratio is 13000:1 based on a measured ON conductance of 6.89 W/K and a calculated OFF conductance of 0.00053 W/K. The mini-ROD-TSW is targeted to have an ON conductance of 1.5 W/K and an OFF conductance of 0.0015 W/K, both verified by analysis. Test verification of the mini-ROD-TSW remains to be carried out. The paper will provide design/performance details of each device.

Farmer, Jeffery T.↗

NASA NTRSDate not supplied

Selection of Alternator Voltage for Dynamic Radioisotope Power Systems

In this paper, we present a study to select an appropriate alternator voltage of the free-piston Stirling convertors (FPSC) for efficient and light Dynamic Radioisotope Power Systems (DRPS). With a system thermal-to-electrical efficiency 3-4 times greater than radioisotope thermoelectric generator (RTG) systems and a higher power density than Brayton systems in the power range of interest for radioisotope-powered systems, Stirling-based DRPS is uniquely suited to benefit upcoming NASA missions. Much effort has been invested in the design and optimization of the thermal, mechanical, and materials aspects of FPSCs, but the electrical aspect has been more nebulous. Therefore, in this paper, a preliminary study will be presented to select the appropriate Stirling alternator voltage to develop a light and efficient system using available flight components. Power conversion systems face a trade between efficiency and system volume/mass with the optimal trade being determined by the application. Neglecting non-idealities related to insulation thickness and winding packing factor and assuming a constant winding area, alternator efficiency is independent of alternator voltage. Because wire size and alternator current can be traded against turn count and alternator voltage without impacting efficiency, the guidance on the optimal design comes from analysis of the controller power electronics and the remainder of the system. Properties of available flight-qualified electrical components, such as rated voltage/current and on-resistance, typically come in discrete values instead of a continuous range of values. With multiple components being required to form the power conversion stage of the controller, each limited to incremental values, a continuous optimization is of little benefit. Instead of a continuous optimization, a random process using properties of the available components can be used to develop a Pareto design front indicating the optimized trade space. The most advantageous trade between system efficiency and mass for the system at hand can then be selected from the range of feasible designs. In the final paper, the design process, assumptions, and preliminary results will be presented.

Free-Piston Stirling Convertor Controller, Dynamic↗

NASA NTRS2022

A Novel High-Performance Mission-Enabling Multi-Purpose Radioisotope Heat Source

Recent studies indicate science mission concepts targeting access to the sub-surface oceans of icy moons require ice-penetrating cryobots powered by advanced Radioisotope Power Systems (RPS). These systems would deliver waste heat for ice-melting in the range of 10 kW. Minimizing the transit time through the kilometers-thick ice shells to just a few years requires these RPS to utilize heat sources having a higher thermal energy volumetric density than the existing flight-qualified General-Purpose Heat Source (GPHS). A Compact Heat Source (CPHS)has been conceptualized in which the graphite impact shells(GIS) of the existing GPHS are rearranged in a hexagonal aeroshell containing seven GIS per module, as opposed to the standard two per module; offering a thermal energy density of 0.57 W/cm3versus 0.29 W/cm3 offered by the GPHS simply from the repackaging of Technology Readiness Level (TRL)9 subassemblies. Preliminary thermal modeling of the CPHS integrated into a notional radioisotope thermoelectric generator(RTG) structure further suggests that centerline temperatures are well within allowable limits during nominal operation. Given the need for the CPHS for a subset of missions, it is worth exploring the applicability of the CPHS for more general RTG purposes. We discuss herein how the CPHS may be implemented with either heritage or in-development thermoelectric converter technologies into a Next-Generation RTG concept. Due to a higher energy density, the legacy heat rejection fin arrangement must be modified to permit a sufficiently low cold-side temperature. Preliminary finite element analysis suggests fin-root temperatures can be kept as low as 520 K while allowing the generator to fit within the usable dimensions of currently available United States Department of Energy shipping containers. Such temperatures would certainly be compatible with the use of high temperature thermoelectric converter technologies.. A prime candidate is the heritage silicon-germanium (SiGe) unicouple, whose design could be adapted by approximately halving the leg-length, but without changes in hot and cold junction interfaces, which are features critical to the proven performance and reliability of these devices. The estimated Beginning of Life power for a SiGe-based CPHS-RTG using 12 CPHS for a thermal inventory of 10.5 kW is greater than 600 W under deep space operating conditions. Using higher performance segmented couples currently in development that are based on skutterudite,La3−xTe4and 14-1-11 Zintl thermoelectric materials in lieu of the SiGe unicouples would increase the power level to more than1 kW. The high specific power (We/kg) attribute of CPHS-RTGs found in this study could potentially enable Radioisotope Electric Propulsion (REP) mission concepts. Past NASA REP mission concept studies identified specific power needs in excess of 6to 8 We/kg. Based on a GPHS-RTG-like system configuration, we show that at fin root temperatures between 530 K and 570K (deep space environment), specific powers exceeding 10 We/kg are achievable using high performance segmented thermoelectric converters. The compact sizing and power density of the CPHS-RTG would constitute a significant step upgrade in specific power when compared to heritage GPHS-RTG (approximately5.1 We/kg) and off-the-shelf Multi-Mission RTG (approximately 2.6 We/kg).

Nesmith, Bill J.↗

NASA NTRSDate not supplied

Lunar Proving Grounds Definition

The Lunar Surface Innovation Consortium (LSIC) is hosting a hybrid Lunar Proving Grounds Definition Workshop, July 12-13,2023, at the Johns Hopkins University Applied Physics Laboratory in Laurel, Maryland, and on Zoom. The topic of facilities needed for testing hardware destined for the Moon and the need for Earth-based ‘Lunar Proving Grounds’ for testing systems has come up across all six Focus Areas of LSIC. While facilities exist for component- and instrument- level technology maturation (e.g., up to system/subsystem demo in relevant environments), and there are potential flight opportunities for component maturation to flight-qualified and even flight-proved systems, the Artemis Program vision for a sustained presence and transition to industry (e.g., the Moon to Mars Objectives and the LSIC “Path to an Enduring Lunar Presence” white paper) suggests an architecture of integrated systems and systems of systems more complex than Apollo or the International Space Station. Some questions we aim to address through this workshop include: (1) How will validation and verification of these systems and interactions, including human-robotic operations, be accomplished? (2) What metrics need to be tested, and thus what capabilities will such a facility or facilities need? (3) Which functionalities can be tested separately and which need to synergize? What can be the role of digital engineering?

Proving Grounds↗