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Overview 1993: Chemical propulsion at CSTAR

Chemical Propulsion at CSTAR continues to expand its activities and areas of interest. Several new initiatives are being developed which are extensions of, or replacements for, earlier projects. One current focus is on reassessing promising engine cycles and the enabling technologies for implementing them. These engine cycles which include advanced hybrids, and staged combustion cycles have the use of oxygen as a working fluid and coolant in common. Oxygen is used as a turbine drive gas, tank pressurant and as a cooling medium for combustion devices. CSTAR has interest in the propellant feed systems for advanced rocket engines, including propellant conditioning and tank pressurization, gas generators, and turbomachinery. CSTAR's interests also include propellant injection into the main chamber. These aspects of rocket propulsion embody a diverse range of technical disciplines and technologies, critical to the pursuit of low cost space access. The chemical propulsion program at CSTAR includes active projects investigating hybrid rocket engine oxygen feed systems, hybrid rocket injectors, gas fed hybrid rocket combustion, elements of main injectors for staged combustion devices. CSTAR is actively seeking industrial partners interested in joint participation in one or more phases of the analyses, design, development and application of propulsion technologies and related technical disciplines.

William H. Knuth

Modeling for Battery Prognostics

For any battery-powered vehicles (be it unmanned aerial vehicles, small passenger aircraft, or assets in exoplanetary operations) to operate at maximum efficiency and reliability, it is critical to monitor battery health as well performance and to predict end of discharge (EOD) and end of useful life (EOL). To fulfil these needs, it is important to capture the battery's inherent characteristics as well as operational knowledge in the form of models that can be used by monitoring, diagnostic, and prognostic algorithms. Several battery modeling methodologies have been developed in last few years as the understanding of underlying electrochemical mechanics has been advancing. The models can generally be classified as empirical models, electrochemical engineering models, multi-physics models, and molecular/atomist. Empirical models are based on fitting certain functions to past experimental data, without making use of any physicochemical principles. Electrical circuit equivalent models are an example of such empirical models. Electrochemical engineering models are typically continuum models that include electrochemical kinetics and transport phenomena. Each model has its advantages and disadvantages. The former type of model has the advantage of being computationally efficient, but has limited accuracy and robustness, due to the approximations used in developed model, and as a result of such approximations, cannot represent aging well. The latter type of model has the advantage of being very accurate, but is often computationally inefficient, having to solve complex sets of partial differential equations, and thus not suited well for online prognostic applications. In addition both multi-physics and atomist models are computationally expensive hence are even less suited to online application An electrochemistry-based model of Li-ion batteries has been developed, that captures crucial electrochemical processes, captures effects of aging, is computationally efficient, and is of suitable accuracy for reliable EOD prediction in a variety of operational profiles. The model can be considered an electrochemical engineering model, but unlike most such models found in the literature, certain approximations are done that allow to retain computational efficiency for online implementation of the model. Although the focus here is on Li-ion batteries, the model is quite general and can be applied to different chemistries through a change of model parameter values. Progress on model development, providing model validation results and EOD prediction results is being presented.

Prognostics

Evaluation of an Ejector Ramjet Based Propulsion System for Air-Breathing Hypersonic Flight

A Rocket Based Combined Cycle (RBCC) engine system is designed to combine the high thrust to weight ratio of a rocket along with the high specific impulse of a ramjet in a single, integrated propulsion system. This integrated, combined cycle propulsion system is designed to provide higher vehicle performance than that achievable with a separate rocket and ramjet. The RBCC engine system studied in the current program is the Aerojet strutjet engine concept, which is being developed jointly by a government-industry team as part of the Air Force HyTech program pre-PRDA activity. The strutjet is an ejector-ramjet engine in which small rocket chambers are embedded into the trailing edges of the inlet compression struts. The engine operates as an ejector-ramjet from takeoff to slightly above Mach 3. Above Mach 3 the engine operates as a ramjet and transitions to a scramjet at high Mach numbers. For space launch applications the rockets would be re-ignited at a Mach number or altitude beyond which air-breathing propulsion alone becomes impractical. The focus of the present study is to develop and demonstrate a strutjet flowpath using hydrocarbon fuel at up to Mach 7 conditions.

Scott R Thomas

Recommended Practice for Use of ExB Probes in Electric Propulsion Testing

An ExB probe is an electric propulsion plume diagnostic that has at its core a Wien filter. Ions entering the instrument experience perpendicular electric and magnetic fields and are filtered based on their velocity. While the ExB probe can be used to estimate the ion velocity distribution function, in the electric propulsion community, it is commonly used to measure species fractions. There are numerous probe designs, implementation and operation procedures, and data analysis approaches described and in use across the community. This paper provides recommendations and descriptions of best practices for design, implementation, and data analysis for the ExB probe, with a particular emphasis on Hall and ion thrusters. This work contributes to the broader community goal to standardize the use of diagnostics in electric propulsion testing.

ExB probe

Skylab M551 Metals Melting Experiment

The objectives of the M551 Metals Melting Experiment are to (a) study behavior of molten metal, (b) characterize metals melted and solidified in the low gravity space environment compared to one-gravity of earth, and (c) determine feasibility of joining metals in space. The experiment used the electron beam (EB) and chamber of the M512 apparatus to make a dwell puddle and a melt in a rotating disc of varying thickness. Hence, the EB performed cut-through, full and partial penetration melts, in addition to a re-solidified button. The three disc materials were aluminum 2219-T87, 304 stainless steel and pure tantalum to provide a wide range of density and melting conditions. Observations to date include (a) the proof that EB welding, cutting and melting can be done successfully in low gravity. Earlier, some welding authorities had postulated that without gravity the EB would force the molten puddle out of contact. However, the experiment proved that surface tension forces predominate. (b) From the view-point of cast-solidification, small, equiaxed grains in Skylab specimens compared to large, elongated grains in ground-based specimens were observed. The former are thought to be associated with constitutional supercooling and nucleation where the latter are associated with dendritic solidification. In further support of the more equiaxed grain growth in Skylab, symmetric sub-grain patterns were frequently observed where there was much less symmetry in ground-based specimens. Further work is being done to explain the differences in solidification.

E C Mckannan

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at up to 6,800 rpm. The first non-rotating tests of the fully assembled HEMM cryocooler have been completed, and initial testing has yielded a no-load temperature of 112 K. A small helium leak into the vacuum system has been identified as the major bottleneck to performance, and based on measurements with the motor turned off there is an observed vacuum-side heat leak of approximately 30 W at 115 K. Immediate next steps for testing are to locate and mitigate the apparent helium leaks into the vacuum chamber. Thus far, compressor performance and the apparent heat lift after correcting for the heat leak are on par with expectations.

Electrified Aircraft Propulsion

Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Battery Assessment

In 2013, the Boeing Company model 787-8 Dreamliner commercial aircraft experienced three catastrophic lithium (Li) battery failures. The cause of each failure resulted in a single-cell thermal runaway (TR) condition, which propagated to adjacent battery cells. Two of the failures involved rechargeable lithium-ion (Li-Ion) batteries, and the third event involved a nonrechargeable lithium-manganese dioxide (Li-MnO2) battery. In response to these Li battery failures, the NASA Engineering and Safety Center (NESC) approved a technical assessment of the International Space Station Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Li non-rechargeable battery. This assessment was conducted to evaluate the SAFER Li nonrechargeable battery safety design features against Boeing 787 Dreamliner Li battery failure lessons learned. Specifically, this investigation focused on assessing the severity of a SAFER battery TR hazard conditions.

Iannello, Christopher J.

Second LDEF Post-Retrieval Symposium Abstracts

These abstracts from the symposium represent the data analysis of the 57 experiments flown on the LDEF. The experiments include materials, coatings, thermal systems, power and propulsion, science, (cosmic ray, interstellar gas, heavy ions, micrometeoroids, etc.), electronics, optics, and life science.

Arlene S. Levine

Novel Polyimide Battery Separator Imbibed with Room-Temperature Ionic Liquids

The journey to Mars will require advancements in many existing technologies, including space power and energy storage systems. According to the 2015 NASA Technology Roadmaps, energy storage is a critical technology area to develop for both terrestrial as well as future long-term space missions. Currently, batteries represent one of the major areas in need of advancement, both in terms of energy density as well as safety. Recently, concerns regarding the fire safety of commercial lithium-ion batteries have prompted efforts to produce nonflammable battery components, namely the electrolyte and separator. Commercial lithium-ion batteries utilize polyolefin separators imbibed with a lithium salt dissolved in cyclic carbonates. This separator/electrolyte combination imparts good ionic conductivities in the range of 10(exp -2) to 10(exp -3) S/cm. However, the cyclic carbonates and polyolefin separator are inherently flammable. Room-temperature ionic liquids (RTILs) appear to be a safer alternative to cyclic carbonates. They offer good ionic conductivities, similar to those observed in cyclic carbonates, but are inherently nonvolatile and nonflammable giving them a safety advantage. Many promising RTILs for battery electrolytes are not compatible with commercial polyolefin separator materials. Polyimide aerogels possess an open-porous, fibrillar network architecture which offers a high degree of porosity (typically greater than 85 porous), required for lithium ion conduction, as well as good mechanical properties. Furthermore, these materials are compatible with all tested RTILs. By creating a polyimide gel and imbibing the gel with a RTIL containing a lithium salt instead of super critically drying them to form aerogels, a nonflammable separator/electrolyte system with conductivities in the range of 1x10(exp -3) S/cm has been demonstrated.

Polyimide

Hot Water, Cold Reality: Feasibility Assessment of Iodine Removal in Heated Spacecraft Potable Water Systems

The current eXploration Potable Water Dispenser (xPWD) design removes iodine upstream of the heated leg due to concerns with the Activated Carbon and Ion Exchange (ACTEX) functionality in hot water, leaving the downstream volume without residual biocide. The NESC determined that this non-iodinated volume is a concern for microbial growth during exploration missions and proposed 33 biocide architecture options for future missions that could address this concern. The top-ranked architecture out of the report was Option 1: moving the iodine removal media as close to the dispensing needle as possible to minimize the wetted components without biocide in the xPWD. Three main challenges were identified with this proposed configuration. First, the hot water at 175 ± 25 °F is a concern for the potential physical degradation of the ion exchange resin and lowered adsorption capacity in activated carbon. Second, moving the ACTEX or alternative sorption media closer to the dispense needle increases the unheated volume downstream of the heater, challenging the ability for dispensed water to meet temperature requirements. Finally, bubbles evolved from dissolved gas coming out of solution in the heater could clog or reduce the efficiency of the sorption media. To address the first challenge, more thermally robust ion exchange resins were identified and adsorption capacity tests were planned and will be discussed in a companion ICES paper (ICES-2026-5). To address the dispense temperature concerns, allowable bed size and architectural configuration changes are proposed. The value of adding phase separators to remove bubbles and potential implementation schemes are discussed. These findings support the development of potable water systems resilient to microbial risks during long-duration space missions.

Biocide

Hot Water, Cold Reality: Feasibility Assessment of Iodine Removal in Heated Spacecraft Potable Water Systems

The current eXploration Potable Water Dispenser (xPWD) design removes iodine upstream of the heated leg due to concerns with the Activated Carbon and Ion Exchange (ACTEX) functionality in hot water, leaving the downstream volume without residual biocide. The NESC determined that this non-iodinated volume is a concern for microbial growth during exploration missions and proposed 33 biocide architecture options for future missions that could address this concern. The top-ranked architecture out of the report was Option 1: moving the iodine removal media as close to the dispensing needle as possible to minimize the wetted components without biocide in the xPWD. Three main challenges were identified with this proposed configuration. First, the hot water at 175 ± 25 °F is a concern for the potential physical degradation of the ion exchange resin and lowered adsorption capacity in activated carbon. Second, moving the ACTEX or alternative sorption media closer to the dispense needle increases the unheated volume downstream of the heater, challenging the ability for dispensed water to meet temperature requirements. Finally, bubbles evolved from dissolved gas coming out of solution in the heater could clog or reduce the efficiency of the sorption media. To address the first challenge, more thermally robust ion exchange resins were identified and adsorption capacity tests were planned and will be discussed in a companion ICES paper (ICES-2026-5). To address the dispense temperature concerns, allowable bed size and architectural configuration changes are proposed. The value of adding phase separators to remove bubbles and potential implementation schemes are discussed. These findings support the development of potable water systems resilient to microbial risks during long-duration space missions.

PWD

Model Correlation and Thermal Analysis of xEMU Boot at Lunar South Pole Temperatures

The National Aeronautics and Space Administration (NASA) Artemis program plans to send astronauts to the lunar south pole, a region of the moon that is colder than previous lunar missions and low earth orbit operations. The spacesuit boots that will be used on these missions will be directly impacted by these extremely cold temperatures (down to ~50 K). To assess the performance of the Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these extreme temperatures, the boot was tested at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This data was used to correlate thermal models to predict operational performance of the boots on the lunar south pole. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU TVAC test. Data from the test series was used to determine expected thermal conductances within the boot and between the boot and environment. These conductances were used to correlate a Thermal Desktop model of the xEMU boot across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. The correlated model was then used to predict operational performance in the lunar south pole. While the predictions indicate promising evidence for performance of the boots at the 100K test point, there is still substantial uncertainty in performance, particularly at the 48K test point. The results of this test series and model correlation stress the importance of improved testing for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

xEMU

Model Correlation and Thermal Analysis of xEMU Boot at Lunar South Pole Temperatures

The National Aeronautics and Space Administration (NASA) Artemis program plans to send astronauts to the lunar south pole, a region of the moon that is colder than previous lunar missions and low earth orbit operations. The spacesuit boots that will be used on these missions will be directly impacted by these extremely cold temperatures (down to ~50 K). To assess the performance of the Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these extreme temperatures, the boot was tested at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This data was used to correlate thermal models to predict operational performance of the boots on the lunar south pole. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU TVAC test. Data from the test series was used to determine expected thermal conductances within the boot and between the boot and environment. These conductances were used to correlate a Thermal Desktop model of the xEMU boot across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. The correlated model was then used to predict operational performance in the lunar south pole. While the predictions indicate promising evidence for performance of the boots at the 100K test point, there is still substantial uncertainty in performance, particularly at the 48K test point. The results of this test series and model correlation stress the importance of improved testing for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

thermal analysis

Sodium Sulfur Battery Cell Experiment (NaSBE)

The Ford Motor Company published papers describing new types of secondary battery comprised of: solid, sodium ion conducting electrolyte; liquid metal electrode; redox electrode; operating temperature between 300 and 400 deg. C; specific energy of 150 Wh/kg; and a nominal voltage of 2.0 V.

Garner, J. Christopher

Ranger Spacecraft

The thermal-control philosophy of the spacecraft currently under development by the Jet Propulsion Laboratory is design by passive means to maintain all components within the tolerances specified by cognizant engineers. Due to the complexity of the configurations, calculations are) of necessity, fairly generalized and final design is based upon tests in an environmental chamber. The Ranger series spacecraft is designed with a basic structure which is common to all models, with additional hardware to suit the individual mission. This basic structure of Rangers A-1 and A-2 is seen as the hexagonal instrument section, the erectable solar panels, the movable antenna, and the omniantenna. The Ranger A-1 and A-2 configuration is for engineering tests and space-exploration, with the scientific instrumentation isolation requirement dictating the spread-out design. The spacecraft stands 12 feet high, weighs 700 to 800 pounds, and has an internal power of 150 watts. Rangers A-3, A-4, and A-5 are designed to rough land a capsule on the moon. For these, a capsule and retrorocket replace the scientific instruments, occupying the space inside the tower structure. The spacecraft must survive many environments. Chronologically they are: 1) Folded configuration inside an aerodynamic shroud on the pad. 2) Thermal flux from shroud aerodynamically heated during boost phase. 3) Coasting up to 30 minutes attached to Agena stage after booster and shroud are separated. 4) Agena stage burning. 5) Coasting and tumbling after separation from Agena until it passes from earth's shadow. 6) Upon reaching sunlight, panels open and begin sun acquisition. 7) Antenna seeks earth after spacecraft locks onto sun. 8) Space phase- "steady state" with vehicle's vertical axis locked on sun, communicating with earth. The philosophy is to design for the sun-acquired mode, making allowances for the transient conditions.

T. O. Thostesen

Predicting Operational Performance of xEMU Boot at Lunar South Pole Temperatures using Thermal Desktop ®

The spacesuit boots that will be used on Artemis lunar south pole surface missions will be exposed to extremely cold temperatures (down to ~50 K). To assess the performance of the government’s Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these permanently shadowed regions, testing was performed at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU CITADEL TVAC test. Expected thermal conductances within the boot and between the boot and environment were calculated from test data, which was then used as an initial guess for conductances within a Thermal Desktop (TD) model. Correlation of the TD model using the internal SOLVER feature was performed across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. Operational performance at the lunar south pole was then predicted using results from the correlated model. While the predictions provide evidence for acceptable performance of the boots at the 100K environment test point, there is still substantial uncertainty in performance, especially at the 48K test point. This uncertainty is due in part to testing limitations such as contacting the foot to a hard metal plate rather than granular regolith, and model limitations such as the lack of a realistic foot model. These limitations and their impacts are addressed in detail in this paper. The results of this test series and model correlation underscore the importance of additional improved testing and modeling for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

Spacesuit

NASA Battery Working Group - 2007-2008: Battery Task Summary Report

This presentation provides a summary of the 2007-2008 NASA Battery Working Group efforts completed in support of the NASA Engineering Safety Center (NESC). The effort covered a series of pro-active tasks that address the following: Binding Procurements -- guidelines related to requirements for the battery system that should be considered at the time of contract award Wet Life of Ni-H2 Batteries -- issues/strategies for effective storage and impact of long-term storage on performance and life Generic Guidelines for Lithium-ion Safety, Handling and Qualification -- Standardized approaches developed and risk assessments (1) Lithium-ion Performance Assessment -- survey of manufacturers and capabilities to meet mission needs. Guidelines document generated (2) Conditions Required for using Pouch Cells in Aerospace Missions -- focus on corrosion, thermal excursions and long-term performance issues. Document defining requirements to maintain performance and life (3) High Voltage Risk Assessment -- focus on safety and abuse tolerance of battery module assemblies. Recommendations of features required for safe implementation (4) Procedure for Determination of Safe Charge Rates -- evaluation of various cell chemistries and recommendation of safe operating regimes for specific cell designs

Manzo, Michelle

Highly Porous Polyimide Gel for Use as Battery Separator with Room Temperature Ionic Liquid Electrolytes

Advanced aerospace vehicular concepts require advances in many existing technologies, including space power and energy storage systems. Batteries represent one of the major areas in need of improvement, both in terms of energy density and safety, with growing concerns over the fire safety of commercial lithium-ion batteries. This has prompted efforts to develop nonflammable battery components, namely the electrolyte and separator. Existing commercial lithium-ion batteries utilize polyolefin microporous membranes as separators with an electrolyte consisting of a lithium salt dissolved in a mixture of cyclic carbonate solvents. This separator/electrolyte combination has ionic conductivities in the range of 10 −2 to 10 −3 S/cm. However, the cyclic carbonate solvents are inherently flammable. Room-temperature ionic liquids (RTILs) appear to be a safer alternative. They offer good ionic conductivities and are inherently nonvolatile and nonflammable, giving them a safety advantage. However, many promising RTILs for battery electrolytes are not compatible with commercial polyolefin separator materials. Alternative separator materials, such as polyimides, are non-flammable and are capable of accepting RTILs into their structure. Polyimide gels, with a composition of 4,4′-oxydianiline, 3,3′,4,4′-tetracarboxylic dianhydride and cross-linked with Desmodur N3300A, possess an open-porous, fibrillar network architecture which offers a high degree of porosity (typically greater than 85% porosity) for lithium-ion transport and conduction, as well as good mechanical properties. Furthermore, these polyimide gels are compatible with selected imidazolium-based RTILs. Nonflammable separator/electrolyte systems with room-temperature conductivities in the range of 10 −3 S/cm have been evaluated. It has been demonstrated that 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide was the most promising among six RTILs screened, in terms of both ionic conductivity and constant current cycling.

Polyimide