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DOE OSTI2024

Development Results on Replacement Materials for Current Scarce or High Supply Chain Risk Materials

In September 2020, the U.S. government issued an executive order to address the threat to the domestic supply chain from its reliance on critical minerals (CMs) from foreign competitors and to support the domestic mining and processing industry. The Advanced Materials and Manufacturing Technology (AMMT) program is addressing this executive order by evaluating advanced manufacturing (AM) and its impact on the demands of CMs for energy production in general and how the deployment of AM in nuclear energy will support the projected goals of the Paris Accord and further a net-zero carbon economy (NZE) by 2050. Three strategic reports were previously prepared by the AMMT program to date and identified two areas for more detailed exploration: (1) the replacement of high-risk CMs such as cobalt and niobium by more abundant minerals and (2) the minimization and utilization of CM waste streams. The design of nuclear materials without critical elements as alloying elements, is a part of the nuclear materials strategy to overcome the critical minerals scarcity. In this report, two approaches are evaluated namely (1) replacement of critical elements as alloying elements in nuclear materials, and (2) the design of a new alloys that does not contain critical minerals as an alloying element.

36 MATERIALS SCIENCE↗

NASA NTRS1973

Combustion detector

A device has been developed for generating a rapid response signal upon the radiation-emitting combustion reaction of certain gases in order to provide a means for the detection and identification of such reaction and concurrently discriminate against spurious signals. This combustion might be the first stage of a coal mine explosion process, and thereby this device could provide a warning of the impending explosion in time to initiate quenching action. This device has the capability of distinguishing between the light emitted from a combustion reaction and the light emitted by miners' lamps, electric lamps, welding sparks or other spurious events so that the quenching mechanism is triggered only when an explosion-initiating combustion occurs.

Trimpi, R. L.↗

NASA NTRS1985

Lunar regolith fines - A source of hydrogen

The theoretical evaluation of the lunar regolith fines as a primary source of hydrogen reveals that a minimum order of magnitude increase in hydrogen content is possible in beneficiated fines because both particle size and particle shape play a significant role in the relationship of volume percent of surface coating to grain size. The lunar regolith fines meet the basic requirement for beneficiation because a major portion (minimum two-thirds) of the hydrogen occurs in the less than 20-micron-size fraction, a relatively small part of the fines. Beneficiation should be accomplished by a combination of vibratory screening followed by cyclone and/or possibly electrostatic separation. Early exploitation of the lunar regolith fines for hydrogen probably will be limited to hydrogen obtained as a by-product or co-product from the mining and processing for other elements or materials because a minimum of about 13,600 tons to about 19,600 tons of 100 ppm hydrogen-bearing lunar regolith fines will have to be processed with about 3,100 tons to about 4,500 tons, respectively, of concentrate heated to supply 1 ton of hydrogen, yielding a recovery of about 74 percent to about 51 percent respectively, of the hydrogen.

Carter, J. L.↗

NASA NTRS1988

Processes and energy costs for mining lunar Helium-3

Preliminary investigations show that obtaining He-3 from the moon is technically feasible and economically viable. With the exception of beneficiation, the proposed procedures are state of the art. Mass of equipment needed from earth is of some concern, but resupply will eventually be ameliorated by the use of titanium from indigenous ilmenite. A complete energy payback from a D/He-3 fusion reactor utilizing lunar He-3 is approx. 80, providing ample incentive for commercial investment is forthcoming. Byproducts will be of great value to the resupply of a permanent lunar base and enhancement of space exploration.

Sviatoslavsky, I. N.↗

NASA NTRS1991

Oxygen extraction from lunar soil by fluorination

Mining and processing of lunar material could possibly lead to more cost-efficient scenarios for permanent presence of man in space and on the Moon. Production of oxygen for use as propellant seems especially important. Different candidate processes for oxygen-extraction from lunar soil were proposed, of which the reduction of ilmenite by hydrogen was studied most. This process, however, needs the concentration of ilmenite from lunar regolith to a large extent and releases oxygen only with low efficiency. Another possibility - the fluorination method - which works with lunar bulk material as feedstock is discussed. Liberation of oxygen from silicate or oxide materials by fluorination methods has been applied in geoscience since the early sixties. The fact that even at moderate temperatures 98 to 100 percent yields can be attained, suggests that fluorination of lunar regolith could be an effective way of propellant production. Lunar soil contains about 50 percent oxygen by weight which is gained nearly completely through this process as O2 gas. The second-most element Si is liberated as gaseous SiF4. It could be used for production of Si-metal and fluorine-recycling. All other main elements of lunar soil will be converted into solid fluorides which also can be used for metal-production and fluorine-recycling. Preliminary results of small scale experiments with different materials are discussed, giving information on specific oxygen-yields and amounts of by-products as functions of temperature. These experiments were performed with an already existing fluorine extraction and collection device at the University of Bonn, normally used for determination of oxygen-isotopic abundances. Optimum conditions, especially concerning energy consumption, are investigated. Extrapolation of the experimental results to large industrial-type plants on the Moon is tried and seems to be promising at first sight. The recycling of the fluorine is, however, crucial for the process. It might be achieved by means of electrolysis. This needs further investigation. The technical problem of transport and handling of the toxic and corrosive fluorine seems to be solvable and could be done by inert storage vessels.

Seboldt, W.↗

NASA NTRS1991

Advantages of the use of lunar and Mars propellant production

The use of nonterrestrial resources is discussed in the context of facilitating the transport of space-vehicle propellant to be used for lunar and/or Mars missions. A cost-benefit analysis is conducted to determine the feasibility and efficiency of developing propellant-production facilities in space for future mission support. The analysis suggests that after 2-3 years a break-even point is possible for return-on-investment mass, and technological hurdles are described that include systems for automation, mining, and processing.

Roberts, Barney↗

NASA NTRS1993

Experimental Determination of in Situ Utilization of Lunar Regolith for Thermal Energy Storage

A Lunar Thermal Energy from Regolith (LUTHER) experiment has been designed and fabricated at the NASA Lewis Research Center to determine the feasibility of using lunar soil as thermal energy storage media. The experimental apparatus includes an alumina ceramic canister (25.4 cm diameter by 45.7 cm length) which contains simulated lunar regolith, a heater (either radiative or conductive), 9 heat shields, a heat transfer cold jacket, and 19 type B platinum rhodium thermocouples. The simulated lunar regolith is a basalt, mined and processed by the University of Minnesota, that closely resembles the lunar basalt returned to earth by the Apollo missions. The experiment will test the effects of vacuum, particle size, and density on the thermophysical properties of the regolith. The properties include melt temperature (range), specific heat, thermal conductivity, and latent heat of storage. Two separate tests, using two different heaters, will be performed to study the effect of heating the system using radiative and conductive heat transfer. The physical characteristics of the melt pattern, material compatibility of the molten regolith, and the volatile gas emission will be investigated by heating a portion of the lunar regolith to its melting temperature (1435 K) in a 10(exp -4) pascal vacuum chamber, equipped with a gas spectrum analyzer. A finite differencing SINDA model was developed at NASA Lewis Research Center to predict the performance of the LUTHER experiment. The analytical results of the code will be compared with the experimental data generated by the LUTHER experiment. The code will predict the effects of vacuum, particle size, and density has on the heat transfer to the simulated regolith.

Richter, Scott W.↗

NASA NTRS1992

Alternative scenarios utilizing nonterrestrial resources

A collection of alternative scenarios that are enabled or substantially enhanced by the utilization of nonterrestrial resources is provided. We take a generalized approach to scenario building so that our report will have value in the context of whatever goals are eventually chosen. Some of the topics covered include the following: lunar materials processing; asteroid mining; lunar resources; construction of a large solar power station; solar dynamic power for the space station; reduced gravity; mission characteristics and options; and tourism.

Eldred, Charles H.↗

NASA NTRS1992

A Combined XRD/XRF Instrument for Lunar Resource Assessment

Robotic surface missions to the Moon should be capable of measuring mineral as well as chemical abundances in regolith samples. Although much is already known about the lunar regolith, our data are far from comprehensive. Most of the regolith samples returned to Earth for analysis had lost the upper surface, or it was intermixed with deeper regolith. This upper surface is the part of the regolith most recently exposed to the solar wind; as such it will be important to resource assessment. In addition, it may be far easier to mine and process the uppermost few centimeters of regolith over a broad area than to engage in deep excavation of a smaller area. The most direct means of analyzing the regolith surface will be by studies in situ. In addition, the analysis of the impact-origin regolith surfaces, the Fe-rich glasses of mare pyroclastic deposits, are of resource interest, but are inadequately known; none of the extensive surface-exposed pyroclastic deposits of the Moon have been systematically sampled, although we know something about such deposits from the Apollo 17 site. Because of the potential importance of pyroclastic deposits, methods to quantify glass as well as mineral abundances will be important to resource evaluation. Combined x ray diffraction (XRD) and x ray fluorescence (XRF) analysis will address many resource characterization problems on the Moon. XRF methods are valuable for obtaining full major-element abundances with high precision. Such data, collected in parallel with quantitative mineralogy, permit unambiguous determination of both mineral and chemical abundances where concentrations are high enough to be of resource grade. Collection of both XRD and XRF data from a single sample provides simultaneous chemical and mineralogic information. These data can be used to correlate quantitative chemistry and mineralogy as a set of simultaneous linear equations, the solution of which can lead to full characterization of the sample. The use of Rietveld methods for XRD data analysis can provide a powerful tool for quantitative mineralogy and for obtaining crystallographic data on complex minerals.

Vaniman, D. T.↗

NASA NTRS1992

Mobile continuous lunar excavation

A novel approach to the concept of lunar mining and the use of in situ oxygen, metallics, and ceramics is presented. The EVA time required to set up, relocate, and maintain equipment, as well as the cost per pound of shipping the mining and processing equipment to the moon are considered. The proposed soil fracturing/loading mechanisms are all based loosely on using the Apollo Lunar Roving Vehicle (LRV) Frame. All use motor driven tracks for mobility in the forward/reverse and left/right direction. All mechanisms employ the concept of rototillers which are attached to a gantry which, through the use of motor-driven lead screws, provide the rototillers with an up/down capability. A self-reactant excavator, a local mass enhanced excavator, and a soil reactant excavator are illustrated.

Paterson, John L.↗

NASA NTRS1997

There's Iron in Them Thar Hills: A Geologic Look at the Aristarchus Plateau as a Potential Landing Site for Human Lunar Return

Lunar pyroclastic deposits are unique among lunar soils. Composed of very fine grained glass beads rich in Fe, Ti and Mg they yield unique spectral signatures. From the spectra two major classes and five subclasses of lunar dark mantling deposits have been identified. Recent work by me and others has shown that the larger regional deposits are more numerous, extensive, thicker, and widely distributed than previously thought, leading us to suggest that they would make ideal resource feedstock for future lunar surface activities. Returned sample studies and the recently collected Galileo and Clementine data also corroborate these findings. Recent planning for return to the Moon indicates that large cost savings can result from using locally produced oxygen, and recent JSC laboratory results indicate that iron-rich pyroclastic dark mantling deposits may be the richest oxygen resource on the Moon. My earlier work demonstrated that instead of using regolith, bulk lunar pyroclastic deposits are better suited for beneficiation as they are thick (lO's m's), unconsolidated, fine-grained deposits. In addition, the lack of rocks and boulders and the typically flat to gently rolling terrain will facilitate their mining and processing. In preparation for the Human Lunar Return (HLR) I have characterized the Aristarchus Plateau (24 deg. N 52 deg. W) as a potential landing site for an in-situ resource utilization (ISRU) demonstration. The geologic diversity and large volume of Fe-rich pyroclastic material present at the Aristarchus site make it an ideal target for extracting O2, H2 and halogens. This paper (1) describes the current understanding of the geology of Aristarchus plateau; (2) describes the resource potential of the Aristarchus plateau; and (3) presents several candidate landing sites on the plateau for future lunar activities.

Coombs, Cassandra R.↗

NASA NTRS1981

A New Tool for Industry

Ultrasonic P2L2 bolt monitor is a new industrial tool, developed at Langley Research Laboratory, which is lightweight, portable, extremely accurate because it is not subject to friction error, and it is cost-competitive with the least expensive of other types of accurate strain monitors. P2L2 is an acronym for Pulse Phase Locked Loop. The ultrasound system which measures the stress that occurs when a bolt becomes elongated in the process of tightening, transmits sound waves to the bolt being fastened and receives a return signal indicating changes in bolt stress. Results are translated into a digital reading of the actual stress on the bolt. Device monitors the bolt tensioning process on mine roof bolts that provide increased safety within the mine. Also has utility in industrial applications.

Source record↗

NASA NTRS1997

Lessons learned studying design issues for lunar and Mars settlements

In a study of lunar and Mars settlement concepts, an analysis was made of fundamental design assumptions in five technical areas against a model list of occupational and environmental health concerns. The technical areas included the proposed science projects to be supported, habitat and construction issues, closed ecosystem issues, the "MMM" issues (mining, material processing, and manufacturing), and the human elements of physiology, behavior, and mission approach. Four major lessons were learned. First it is possible to relate public health concerns to complex technological development in a proactive design mode, which has the potential for long-term cost savings. Second, it became very apparent that prior to committing any nation or international group to spending the billions to start and complete a lunar settlement, over the next century, that a significantly different approach must be taken from those previously proposed, to solve the closed ecosystem and "MMM" problems. Third, it also appears that the health concerns and technology issues to be addressed for human exploration into space are fundamentally those to be solved for human habitation of the Earth (as a closed ecosystem) in the 21st century. Finally, it is proposed that ecosystem design modeling must develop new tools, based on probabilistic models as a step up from closed circuit models.

Life Support Systems↗

NASA NTRS2004

Investigations of Particle Velocities in a Slurry Pump Using PIV: The Tongue and Adjacent Channel Flow - Part 1

Transport of solid-liquid slurries in pipeline transport over short and medium distances is very important in many industries, including mining related processes. The particle image velocimetry technique was successfully utilized to investigate the velocities and kinetic energy fluctuations of slurry particles at the tongue region of an optically-clear centrifugal pump. The experiments were conducted using 500 micron glass beads at volumetric Concentrations of 2.5% and 5% and at pump speeds of 725 rpm and 1000 rpm. The fluctuation kinetic energy increased approximately 200% to 500% as the pump speed was increased from 725 rpm to IO00 rpm. The directional impingement mechanism is more significant at the pressure side of the blade, tongue and the casing. This mechanism becomes more important as the speed increases. This suggests that the impeller; tongue and the casing of the slurry pump can wear out quickly, especially with an increase in speed. In this paper the emphasis is on the tongue region. The random impingement mechanism caused by the fluctuation kinetic energy of the solids can play an important role on the erosion of the tongue area.

Kadambi, Jaikrishnan R.↗

NASA NTRS2009

A Survey of Terrestrial Approaches to the Challenge of Lunar Dust Containment

Numerous technical challenges exist to successfully extend lunar surface exploration beyond the tantalizing first steps of Apollo. Among these is the challenge of lunar dust intrusion into the cabin environment. Addressing this challenge includes the design of barriers to intrusion as well as techniques for removing the dust from the cabin atmosphere. Opportunities exist for adapting approaches employed in dusty industrial operations and pristine manufacturing environments to cabin environmental quality maintenance applications. A survey of process technologies employed by the semiconductor, pharmaceutical, food processing, and mining industries offers insight into basic approaches that may be suitable for adaptation to lunar surface exploration applications.

Aguilera, Tatiana↗

NASA NTRS2011

Experimental Testing and Modeling of a Pneumatic Regolith Delivery System for ISRU

Excavating and transporting planetary regolith are examples of surface activities that may occur during a future space exploration mission to a planetary body. Regolith, whether it is collected on the Moon, Mars or even an asteroid, consists of granular minerals, some of which have been identified to be viable resources that can be mined and processed chemically to extract useful by-products, such as oxygen, water, and various metals and metal alloys. Even the depleted "waste" material from such chemical processes may be utilized later in the construction of landing pads and protective structures at the site of a planetary base. One reason for excavating and conveying planetary regolith is to deliver raw regolith material to in-situ resource utilization (ISRU) systems. The goal of ISRU is to provide expendable supplies and materials at the planetary destination, if possible. An in-situ capability of producing mission-critical substances such as oxygen will help to extend the mission and its success, and will greatly lower the overall cost of a mission by either eliminating, or significantly reducing, the need to transport the same expendable materials from the Earth. In order to support the goals and objectives of present and future ISRU projects, NASA seeks technology advancements in the areas of regolith conveying. Such systems must be effective, efficient and provide reliable performance over long durations while being exposed to the harsh environments found on planetary surfaces. These conditions include contact with very abrasive regolith particulates, exposure to high vacuum or dry (partial) atmospheres, wide variations in temperature, reduced gravity, and exposure to space radiation. Regolith conveying techniques that combine reduced failure modes and low energy consumption with high material transfer rates will provide significant value for future space exploration missions to the surfaces of the moon, Mars and asteroids. Pneumatic regolith conveying has demonstrated itself to be a viable delivery system through testing under terrestrial and reduced gravity conditions in recent years. Modeling and experimental testing have been conducted at NASA Kennedy Space Center to study and advance pneumatic planetary regolith delivery systems in support of NASA's ISRU project. The goal of this work is to use the model to predict solid-gas flow patterns in reduced gravity environments for ISRU inlet gas line allowing the eductor inlet gas flow to vary and depend on the flow pattern developed at the eductor as inferred by the experimental observations.

Santiago-Maldonado, Edgardo↗

NASA NTRS2011

NASA Instrument Cost/Schedule Model

NASA's Office of Independent Program and Cost Evaluation (IPCE) has established a number of initiatives to improve its cost and schedule estimating capabilities. 12One of these initiatives has resulted in the JPL developed NASA Instrument Cost Model. NICM is a cost and schedule estimator that contains: A system level cost estimation tool; a subsystem level cost estimation tool; a database of cost and technical parameters of over 140 previously flown remote sensing and in-situ instruments; a schedule estimator; a set of rules to estimate cost and schedule by life cycle phases (B/C/D); and a novel tool for developing joint probability distributions for cost and schedule risk (Joint Confidence Level (JCL)). This paper describes the development and use of NICM, including the data normalization processes, data mining methods (cluster analysis, principal components analysis, regression analysis and bootstrap cross validation), the estimating equations themselves and a demonstration of the NICM tool suite.

JCL↗

NASA NTRS2017

Extraction of Volatiles from Regolith or Soil on Mars, the Moon, and Asteroids

NASA's Advanced Exploration Systems ISRU Technology Project is evaluating concepts to extract water from all resource types Near-term objectives: Produce high-fidelity mass, power, and volume estimates for mining and processing systems Identify critical challenges for development focus Begin demonstration of component and subsystem technologies in relevant environment Several processor types: Closed processors either partially or completely sealed during processing Open air processors operates at Mars ambient conditions In-situ processors Extract product directly without excavation of raw resource Design features Elimination of sweep gas reduces dust particles in water condensate Pressure maintained by height of soil in hopper Model developed to evaluate key design parameters Geometry: conveyor diameter, screw diameter, shaft diameter, flight spacing and pitch Operational: screw speed vs. screw length (residence time) Thermal: Heat flux, heat transfer to soil Testing to demonstrate feasibility and performance Agglomeration, clogging Pressure rise forced flow to condenser.

Extration↗