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NASA NTRSDate not supplied

Source Contaminant Control System Design, Operation, and Testing for the Trash Compaction and Processing System

The Trash Compaction and Processing System (TCPS) aims to reduce volume, biologically safen, physically stabilize, manage effluents, and recover resources from astronaut trash in the International Space Station (ISS). This process involves heating the trash to high temperatures, which in turn releases gaseous contaminants. Effluent management scenarios involve releasing these gases back to the ISS cabin after processing and/or directly venting these gases out to space via the Vacuum Exhaust System (VES). Concerns for recovering the gases back to cabin are crew health, safety, and spacecraft environmental impact. The Heat Melt Compactor (HMC) at NASA Ames Research Center (ARC) serves as a test system that supports TCPS development by conducting risk reduction activities associated with an ISS flight demonstration. Previous gas effluent studies were conducted on the HMC. The results consisted of contaminants from the trash exhaust to exceed Spacecraft Maximum Allowable Concentrations (SMAC), which are selected airborne contaminants that can elicit toxicity symptoms to crewmembers via exposure. The Source Contaminant Control System (SCCS) aims to reduce that risk by converting the contaminants into carbon dioxide (CO2) and water (H2O) vapor. The SCCS is composed of a carbon adsorbent bed, to avoid catalyst poisoning, and a catalytic oxidizer (CatOx), which promotes oxidation of the contaminants to CO2and H2O. In turn, the gases coming out of the SCCS should be compatible to the ISS cabin and systems such as the Trace Contaminant Control System (TCCS). Preparation for SCCS testing alongside the HMC Gen 3 are currently underway at ARC. The main objectives are to evaluate CatOx efficiency by CO2conversion and characterize effectiveness of removal by comparing contaminant results before and after CatOx. This paper will report on the SCCS design, operation, and testing with results.

TCPS↗
NASA NTRS1993

Plasma arc welding repair of space flight hardware

A technique to weld repair the main combustion chamber of Space Shuttle Main Engines has been developed. The technique uses the plasma arc welding process and active cooling to seal cracks and pinholes in the hot-gas wall of the main combustion chamber liner. The liner hot-gas wall is made of NARloy-Z, a copper alloy previously thought to be unweldable using conventional arc welding processes. The process must provide extensive heat input to melt the high conductivity NARloy-Z while protecting the delicate structure of the surrounding material. The higher energy density of the plasma arc process provides the necessary heat input while active water cooling protects the surrounding structure. The welding process is precisely controlled using a computerized robotic welding system.

Hoffman, David S.↗
NASA NTRSDate not supplied

Updated Analysis of the Trash Compaction and Processing System: Water Collected from Trash, Evaluation of the Source Contaminant Control System, and Zotek® F30 Foam Processing

The Trash Compaction and Processing System (TCPS) aims to reduce volume, biologically safen, physically stabilize, manage effluents, and recover resources from astronaut trash in the International Space Station (ISS). At NASA Ames Research Center (ARC), there are two test systems: the Heat Melt Compactor (HMC), which compacts the trash into a tile with temperature and pressure, and the Source Contaminant Control System (SCCS), which is the gas management subsystem aimed to reduce contaminants by converting them into carbon dioxide (CO 2 ) and water (H 2 O) vapor. Both the HMC and SCCS serve as test systems that support TCPS development by conducting risk reduction activities associated with an ISS technology demonstration. In this paper, the risk reduction activities discussed are the testing of different trash models for operational scenarios in the HMC, investigating the water extracted from those trash models, and managing the gaseous effluents from the trash via contaminant conversion through the SCCS. The HMC has undergone several tests of different trash models and cases in which a containment bag is used or not. For the first topic, this paper will analyze the water collected and recovered from these tests and analyze the effect of specific trash containment bags. For the second topic, this paper will individually evaluate the carbon bed and catalytic oxidizer (CatOx) to understand what components the carbon bed removes and what contaminants are converted in the CatOx. For the third and final topic, this paper will discuss Zotek® F30 foam processing in the HMC unit and testing verification in correlation to defined TCPS requirements. A foam model was added to reduce the volume of foam that take up space in the ISS. Overall, this paper is a compilation and an updated analysis of tests conducted in the lab-scale TCPS at ARC within the past year.

TCPS↗
NASA NTRSDate not supplied

Source Contaminant Control System Design, Operation, and Testing for the Trash Compaction and Processing System

The Trash Compaction and Processing System (TCPS) aims to reduce volume, biologically safen, physically stabilize, manage effluents, and recover resources from astronaut trash in the International Space Station (ISS). This process involves heating the trash to high temperatures, which in turn releases gaseous contaminants. Effluent management scenarios involve releasing these gases back to the ISS cabin after processing and/or directly venting these gases out to space via the Vacuum Exhaust System (VES). Concerns for recovering the gases back to cabin are crew health, safety, and spacecraft environmental impact. The Heat Melt Compactor (HMC) at NASA Ames Research Center (ARC) serves as a test system that supports TCPS development by conducting risk reduction activities associated with an ISS flight demonstration. Previous gas effluent studies were conducted on the HMC. The results consisted of contaminants from the trash exhaust to exceed Spacecraft Maximum Allowable Concentrations (SMAC), which are selected airborne contaminants that can elicit toxicity symptoms to crewmembers via exposure. The Source Contaminant Control System (SCCS) aims to reduce that risk by converting the contaminants into carbon dioxide (CO2) and water (H2O) vapor. The SCCS is composed of a carbon adsorbent bed, to avoid catalyst poisoning, and a catalytic oxidizer (CatOx), which promotes oxidation of the contaminants to CO2 and H2O. In turn, the gases coming out of the SCCS should be compatible to the ISS cabin and systems such as the Trace Contaminant Control System (TCCS). Preparation for SCCS testing alongside the HMC Gen 3 are currently underway at ARC. The main objectives are to evaluate CatOx efficiency by CO2 conversion and characterize effectiveness of removal by comparing contaminant results before and after CatOx. This paper will report on the SCCS design, operation, and testing with results.

Janine Young↗
NASA NTRSDate not supplied

Water Collection, Recovery, and Bag Containment Analysis of Trash Models of the Trash Compaction and Processing System (TCPS)

The Trash Compaction and Processing System (TCPS) aims to reduce volume, biologically safen, physically stabilize, manage effluents, and recover resources from astronaut trash in the International Space Station (ISS). The Heat Melt Compactor (HMC) at NASA Ames Research Center (ARC) serves as a test system that supports TCPS development by conducting risk reduction activities associated with an ISS flight demonstration. One of the resources desired to be recovered is water from the trash. The HMC Gen 3 has undergone several tests of different trash models and cases in which a containment bag is used or not. This paper will analyze the water collected and recovered from these tests and analyze the effect of specific trash containment bags.

Janine Criselda Young↗
NASA NTRSDate not supplied

Zotek® F30 Foam Processing in the Trash Compaction and Processing System (TCPS)

The Trash Compaction and Processing System (TCPS) aims to reduce volume, biologically safen, physically stabilize, manage effluents, and recover resources from astronaut trash in the International Space Station (ISS). The Heat Melt Compactor (HMC) at NASA Ames Research Center (ARC) serves as a test system that supports TCPS development by conducting risk reduction activities associated with an ISS flight demonstration. One of the risk reduction activities is to test processing for other types of trash models. A foam model was added to reduce the volume of foam that takes up space in the ISS. This paper will discuss Zotek® F30 foam processing in the HMC unit and testing verification in correlation to defined TCPS requirements.

Janine Criselda Young↗
NASA NTRSDate not supplied

Zotek® F30 Foam Processing in the Trash Compaction and Processing System

The Trash Compaction and Processing System (TCPS) aims to reduce volume, biologically safen, physically stabilize, manage effluents, and recover resources from astronaut trash in the International Space Station (ISS). The Heat Melt Compactor (HMC) at NASA Ames Research Center (ARC) serves as a test system that supports TCPS development by conducting risk reduction activities associated with an ISS flight demonstration. One of the risk reduction activities is to test processing for other types of trash models. A foam model was added to reduce the volume of foam that takes up space in the ISS. This paper will discuss Zotek® F30 foam processing in the HMC unit and testing verification in correlation to defined TCPS requirements.

Janine Young↗
NASA NTRS1997

Partitioning of Moderately Siderophile Elements Among Olivine, Silicate Melt, and Sulfide Melt: Constraints on Core Formation in the Earth and Mars

This study investigates the effects of Variations in the fugacities of oxygen and sulfur on the partitioning of first series transition metals (V, Cr, Mn, Fe, Co, Ni. and Cu) and W among coexisting sulfide melt, silicate melt, and olivine. Experiments were performed at 1 atm pressure, 1350 C, with the fugacities of oxygen and sulfur controlled by mixing CO2, CO, and SO2 gases. Starting compositions consisted of a CaO-MgO-Al2O3-SiO2-FeO-Na2O analog for a barred olivine chondrule from an ordinary chondrite and a synthetic komatiite. The f(sub O2)/f(sub S2), conditions ranged from log of f(sub O2) = -7.9 to - 10.6, with log of f(sub S2) values ranging from - 1.0 to -2.5. Our experimental results demonstrate that the f(sub O2)/f(sub S2) dependencies of sulfide melt/silicate melt partition coefficients for the first series transition metals arc proportional to their valence states. The f(sub O2)/f(sub S2) dependencies for the partitioning of Fe, Co, Ni, and Cu are weaker than predicted on the basis of their valence states. Variations in conditions have no significant effect on olivine/melt partitioning other than those resulting from f(sub O2)-induced changes in the valence state of a given element. The strong f(sub O2)/f(sub S2) dependence for the olivine/silicate melt partitioning of V is attributable to a change of valence state, from 4+ to 3+, with decreasing f(sub O2). Our experimentally determined partition coefficients are used to develop models for the segregation of sulfide and metal from the silicate portion of the early Earth and the Shergottite parent body (Mars). We find that the influence of S is not sufficient to explain the overabundance of siderophile and chalcophile elements that remained in the mantle of the Earth following core formation. Important constraints on core formation in Mars are provided by our experimental determination of the partitioning of Cu between silicate and sulfide melts. When combined with existing estimates for siderophile element abundances in the Martian mantle and a mass balance constraint from Fe, the experiments allow a determination of the mass of the Martian core (approx. 17 to 22 wt% of the planet) and its S content (approx.0.4 wt%). These modeling results indicate that Mars is depleted in S, and that its core is solid.

Gaetani, Glenn A.↗
NASA NTRS2013

Heat Melt Compaction as an Effective Treatment for Eliminating Microorganisms from Solid Waste

One of the technologies being tested at NASA Ames Research Center (ARC) for the Advance Exploration Systems program and as part of the logistics and repurposing project is heat melt compaction (HMC) of solid waste. Reduces volume, removes water and renders a biologically stable and safe product. The HMC compacts and reduces the trash volume as much as 90o/o greater than the current manual compaction used by the crew.The project has three primary goals or tasks. 1. Microbiological analysis of HMC hardware surfaces before and after operation. 2. Microbiological and physical characterizations of heat melt tiles made from trash at different processing times and temperatures. 3. Long term storage and stability of HMC trash tiles or "Do the bugs grow back?"

Hummerick, Mary P.↗
NASA NTRS2012

Microbial Characterization Space Solid Wastes Treated with a Heat Melt Compactor

The on going purpose of the project efforts was to characterize and determine the fate of microorganisms in space-generated solid wastes before and after processing by candidate solid waste processing. For FY 11, the candidate technology that was assessed was the Heat Melt Compactor (HMC). The scope included five HMC. product disks produced at ARC from either simulated space-generated trash or from actual space trash, Volume F compartment wet waste, returned on STS 130. This project used conventional microbiological methods to detect and enumerate microorganisms in heat melt compaction (HMC) product disks as well as surface swab samples of the HMC hardware before and after operation. In addition, biological indicators were added to the STS trash prior to compaction in order to determine if these spore-forming bacteria could survive the HMC processing conditions, i.e., high temperature (160 C) over a long duration (3 hrs). To ensure that surface dwelling microbes did not contaminate HMC product disk interiors, the disk surfaces were sanitized with 70% alcohol. Microbiological assays were run before and after sanitization and found that sanitization greatly reduced the number of identified isolates but did not totally eliminate them. To characterize the interior of the disks, ten 1.25 cm diameter core samples were aseptically obtained for each disk. These were run through the microbial characterization analyses. Low counts of bacteria, on the order of 5 to 50 per core, were found, indicating that the HMC operating conditions might not be sufficient for waste sterilization. However, the direct counts were 6 to 8 orders of magnitude greater, indicating that the vast majority of microbes present in the wastes were dead or non-cultivable. An additional indication that the HMC was sterilizing the wastes was the results from the added commercial spore test strips to the wastes prior to HMC operation. Nearly all could be recovered from the HMC disks post-operation and all were showed negative growth when run through the manufacturer's protocol, meaning that the 106 or so spores impregnated into the strips were dead. Control test strips, i.e., not exposed to the HMC conditions were all strongly positive. One area of concern is that the identities of isolates from the cultivable counts included several human pathogens, namely Staphylococcus aureus. The project reported here provides microbial characterization support to the Waste Management Systems element of the Life Support and Habitation Systems program.

Strayer, Richard F.↗
NASA NTRS1986

A mechanical property and stress corrosion evaluation of VIM-ESR-VAR work strengthened and direct double aged Inconel 718 bar material

Presented are the mechanical properties and the stress corrosion resistance of triple melted vacuum induction melted (VIM), electro-slag remelted (ESR), and vacuum arc remelted (VAR), solution treated, work strengthened and direct double aged Inconel 718 alloy bars 4.00 in. (10.16) and 5.75 in. (14.60 cm) diameter. Tensile, charpy v-notched impact, and compact tension specimens were tested at ambient temperature in both the longitudinal and transverse directions. Longitudinal tensile and yield strengths in excess of 220 ksi (1516.85 MPa) and 200 ksi (1378.00 MPa) respectively, were realized at ambient temperature. Additional charpy impact and compact tension tests were performed at -100 F (-73 C). Longitudinal charpy impact strength equalled or exceeded 12.0 ft-lbs (16.3 Joules) at ambient and at -100 F(-73 C) while longitudinal compact (LC) tension fracture toughness strength remained above 79 ksi (86.80 MPa) at ambient and at -100 F(-73 C) temperatures. No failures occurred in the longitudinal or transverse tensile specimens stressed to 75 and 100 percent of their respective yield strengths and exposed to a salt fog environment for 180 days. Tensile tests performed after the stress corrosion test indicated no mechanical property degradation.

Montano, J. W.↗
NASA NTRS1992

The effectiveness of Coriolis dampening of convection during aircraft high-g arcs

Directional solidification data for metal samples in KC-135 parabolic maneuvers are examined to determine evidence for Coriolis dampening of convection. Microstructural and materials properties data are examined for iron carbon, immiscible, and superalloy systems. By comparison of low-g data and high-g data with those of one-g control samples, it is determined that there is no evidence that Coriolis dampening of convective flow is effective during the 1.8 g KC-135 high-g maneuvers. A first approximation model for the high-g arc is proposed. The model yields a centrifugal radius of 20,480 ft and an angular speed of 0.397 RPM. Comparison to centrifugal solidification experiments (for an equal acceleration) where Coriolis melt growth stabilization is significant indicates that the KC-135 high-g arc is less effective in dampening convection by a factor of 100. This large difference in Coriolis dampening of convection might be taken advantage of for experiments where separation of centrifugal acceeration and Coriolis acceleration is desirable.

Curreri, Peter A.↗
NASA NTRS1994

Subduction of hydrated basalt of the oceanic crust: Implications for recycling of water into the upper mantle and continental growth

Subduction zones are presently the dominant sites on Earth for recycling and mass transfer between the crust and mantle; they feed hydrated basaltic oceanic crust into the upper mantle, where dehydration reactions release aqueous fluids and/or hydrous melts. The loci for fluid and/or melt generation will be determined by the intersection of dehydration reaction boundaries of primary hydrous minerals within the subducted lithosphere with slab geotherms. For metabasalt of the oceanic crust, amphibole is the dominant hydrous mineral. The dehydration melting solidus, vapor-absent melting phase relationships; and amphibole-out phase boundary for a number of natural metabasalts have been determined experimentally, and the pressure-temperature conditions of each of these appear to be dependent on bulk composition. Whether or not the dehydration of amphibole is a fluid-generating or partial melting reaction depends on a number of factors specific to a given subduction zone, such as age and thickness of the subducting oceanic lithosphere, the rate of convergence, and the maturity of the subduction zone. In general, subduction of young, hot oceanic lithosphere will result in partial melting of metabasalt of the oceanic crust within the garnet stability field; these melts are characteristically high-Al2O3 trondhjemites, tonalites and dacites. The presence of residual garnet during partial melting imparts a distinctive trace element signature (e.g., high La/Yb, high Sr/Y and Cr/Y combined with low Cr and Y contents relative to demonstrably mantle-derived arc magmas). Water in eclogitized, subducted basalt of the oceanic crust is therefore strongly partitioned into melts generated below about 3.5 GPa in 'hot' subduction zones. Although phase equilibria experiments relevant to 'cold' subduction of hydrated natural basalts are underway in a number of high-pressure laboratories, little is known with respect to the stability of more exotic hydrous minerals (e.g., ellenbergite) and the potential for oceanic crust (including metasediments) to transport water deeper into the mantle.

Rapp, R. P.↗
NASA NTRS1988

The effect of thicker oceanic crust in the Archaean on the growth of continental crust through time

Present crustal evolution models fail to account for the generation of the large volume of continental crust in the required time intervals. All Archaean plate tectonic models, whether invoking faster spreading rates, similar to today's spreading rates, or longer ridge lengths, essentially propose that continental crust has grown by island arc accretion due to the subduction of oceanic crust. The petrological differences that characterize the Archaean from later terrains result from the subduction of hotter oceanic crust into a hotter mantle. If the oceanic crust was appreciably thicker in the Archaean, as geothermal models would indicate, this thicker crust is surely going to have an effect on tectonic processes. A more valid approach is to compare the possible styles of convergence of thick oceanic crust with modern convergence zones. The best modern analog occurs where thick continental crust is colliding with thick continental crust. Oceanic crustal collision on the scale of the present-day Himalayan continental collision zone may have been a frequent occurrence in the Archaean, resulting in extensive partial melting of the hydrous underthrust oceanic crust to produce voluminous tonalite melts, leaving a depleted stabilized basic residuum. Present-day island arc accretion may not have been the dominant mechanism for the growth of the early Archaean crust.

Wilks, M. E.↗
NASA NTRSDate not supplied

Investigating Material Behavior in Atmospheric Entry Conditions: Arc-Jet Testing Insights from Meteorite Ablation to High-Temperature Coatings.

Arc-jet testing is an indispensable tool in elucidating the complex interactions materials undergo when subjected to the extreme thermal and mechanical stresses of atmospheric entry. By replicating these harsh conditions, arc-jets enable researchers to explore critical phenomena such as ablation, melting, and spallation, generating invaluable data that informs the development of sophisticated, physics-based models. These models are pivotal not only in predicting material performance for spacecraft re-entry systems but also in assessing the threat posed by celestial bodies as they encounter Earth’s atmosphere. One of the leading facilities for such investigations is the Hypersonic Materials Environmental Test System (HyMETS) at NASA’s Langley Research Center. A pioneering test campaign conducted at HyMETS focused on unraveling the ablation mechanisms of an ordinary chondrite meteorite (Tamdakht H5) and a terrestrial analog (basalt). These studies unveiled distinct material behaviors: Tamdakht demonstrated a remarkably stable melt flow, with mass loss primarily driven by the volatilization of elements such as iron and sodium, whereas basalt exhibited more aggressive surface degradation due to the rapid decomposition of hydrated minerals, culminating in significant spallation and surface material ejection. Beyond meteorite analysis, HyMETS has also been integral in the exploration of advanced Thermal Protection Systems (TPS) such as Phenolic Impregnated Carbon Ablator (PICA), a material with extensive flight heritage in missions like Stardust, Mars Science Laboratory, Mars 2020, and Osiris-REx. PICA, when coated with NuSil CV-1144-0—a polysiloxane resin designed to prevent particle shedding—undergoes a remarkable transformation upon heating. The resin pyrolyzes to form a thin, oxidation-resistant silicon oxycarbide layer that profoundly influences the material’s thermal response through a sophisticated four-stage process. Initially, the silicon oxycarbide acts as a formidable barrier, impeding reactive interactions with the PICA char and effectively suppressing surface temperature rise and material recession. However, as the heating persists, the protective layer decomposes via carbothermal reduction, exposing the underlying char, which in turn leads to a dramatic spike in surface temperature and accelerated material erosion. In the final stage, equilibrium is reached, with recession rates aligning with those of the virgin material. This intricate understanding of PICA-NuSil behavior under extreme conditions offers valuable insights, enhancing material response models and advancing the development of next-generation TPS for space exploration.

Chemistry↗
NASA NTRS1991

Phenomenological and experimental study of the thermal response of low density silica ablators to high enthalpy plasma flows

A complete analysis of the melting-ablator governing equations is carried out for porous ablators with the purpose of establishing an approximate analytical model capable of determining surface recession, temperature, and heat flux as well as in-depth temperature profiles. A detailed dimensional analysis of the melt-flow governing equations is performed for parameters applicable to high-enthalpy flows. Results of arc-jet flow experiments performed on NASA Reusable Surface Insulation materials of different densities and over a range of stagnation pressures and heat fluxes are discussed. A dimensionless correlation for melt run-offs is derived in terms of material and flow parameters; however, it is pointed out that the accuracy of the current data is sufficient to conclude the compliance with the model.

Henline, William D.↗
NASA NTRS1988

The Petrogenetic significance of Plagioclase megacrysts in Archean rocks

The petrogenetic significance of plagioclase megacryst-bearing Archean rocks was considered. It was suggested that these developed in mid-to upper-crustal magma chambers that were repeatedly replenished. Crystallization of megacrysts from a primitive liquid that evolves to an Fe-rich tholeiite (with LREE enrichment) is nearly isothermal and is an equilibrium process. Cumulates probably form near the margins of the chambers and liquids with megacrysts are periodically extracted and can appear as volcanics. Some flows and intrusives are found in arc-like settings in greenstone belts. Megacrystic dikes represent large volumes of melt and dike swarms such as the Metachawan swarm of Ontario suggest multiple sources of similar compositions. A complex series of melt ponding and migration are probable and involve large amounts of liquid.

Morrison, D. A.↗
NASA NTRS2008

Thermal Stir Welding Development at Marshall Space Flight Center

Solid state welding processes have become the focus of welding process development at NASA's Marshall Space Flight Center. Unlike fusion weld processes such as tungsten inert gas (TIG), variable polarity plasma arc (VPPA), electron beam (EB), etc., solid state welding processes do not melt the material during welding. The resultant microstructure can be characterized as a dynamically recrystallized morphology much different than the casted, dentritic structure typical of fusion weld processes. The primary benefits of solid state processes over fusion weld processes include superior mechanic properties and the elimination of thermal distortion and residual stresses. These solid state processes attributes have profoundly influenced the direction of advanced welding research and development within the NASA agency. Thermal Stir Welding (TSW) is a new solid state welding process being developed at the Marshall Space Flight Center. Unlike friction stir welding, the heating, stirring and forging elements of the weld process can be decoupled for independent control. An induction coil induces energy into a workpiece to attain a desired plastic temperature. An independently controlled stir rod, captured within non-rotating containment plates, then stirs the plasticized material followed by forging plates/rollers that work the stirred weld joint. The independent control (decoupling) of heating, stirring and forging allows, theoretically, for the precision control of microstructure morphology. The TSW process is being used to evaluate the solid state joining of Haynes 230 for ARES J-2X applications. It is also being developed for 500-in (12.5 mm) thick commercially pure grade 2 titanium for navy applications. Other interests include Inconel 718 and stainless steel. This presentation will provide metallurgical and mechanical property data for these high melting temperature alloys.

Ding, Robert J.↗