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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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At least 109 records · Page 6

[No Title]

Adequate performance was achieved relatively early in the development of ion engines and most subsequent development programs have focussed on demonstrating adequate engine life. The primary threats to engine reliability over the required service life are damage accumulation failure modes such as accelerator grid failure due to sputter erosion from charge exchange ions, erosion of discharge chamber components by lower energy ion sputtering and grid shorting by flakes of sputter-deposited material. These types of failure may typically be observed only after thousands of hours of operation. The purpose of this paper is to provide a critical review of the approaches used in past ion engine development programs to characterize and control these wearout failure mechanisms.

Ion Engine↗

High Thermal Conductivity Polymer Matrix Composites (PMC) for Advanced Space Radiators

High temperature polymer matrix composites (PMC) reinforced with high thermal conductivity (approx. 1000 W/mK) pitch-based carbon fibers are evaluated for a facesheet/fin structure of large space radiator systems. Significant weight reductions along with improved thermal performance, structural integrity and space durability toward its metallic counterparts were envisioned. Candidate commercial resin systems including Cyanate Esters, BMIs, and polyimide were selected based on thermal capabilities and processability. PMC laminates were designed to match the thermal expansion coefficient of various metal heat pipes or tubes. Large, but thin composite panels were successfully fabricated after optimizing cure conditions. Space durability of PMC with potential degradation mechanisms was assessed by simulated thermal aging tests in high vacuum, 1-3 x 10(exp -6) torr, at three temperatures, 227 C, 277 C, and 316 C for up to one year. Nanocomposites with vapor-grown carbon nano-fibers and exfoliated graphite flakes were attempted to improve thermal conductivity (TC) and microcracking resistance. Good quality nanocomposites were fabricated and evaluated for TC and durability including radiation resistance. TC was measured in both in-plan and thru-the-thickness directions, and the effects of microcracks on TC are also being evaluated. This paper will discuss the systematic experimental approaches, various performance-durability evaluations, and current subcomponent design and fabrication/manufacturing efforts.

Shin, E. Eugene↗

Lead-acid battery

A light weight lead-acid battery (30) having a positive terminal (36) and a negative terminal (34) and including one or more cells or grid stacks having a plurality of vertically stacked conductive monoplates (10, 20) with positive active material and negative active material deposited on alternating plates in the cell or grid stack. Electrolyte layers (26, 28) positioned between each monoplate are included to provide a battery cell having four sides which is capable of being electrically charged and discharged. Two vertical positive bus bars (42, 43) are provided on opposite sides of the battery cell for connecting the monoplates (10) with positive active material together in parallel current conducting relation. In addition, two negative bus bars (38, 39) on opposite sides of the battery cell each being adjacent the positive bus bars are provided for connecting the monoplates (20) with negative active material together in parallel current conducting relation. The positive (42, 43) and negative (38, 39) bus bars not only provide a low resistance method for connecting the plurality of conductive monoplates of their respective battery terminals (36, 34) but also provides support and structural strength to the battery cell structure. In addition, horizontal orientation of monoplates (10, 20) is provided in a vertical stacking arrangement to reduce electrolyte stratification and short circuiting due to flaking of positive and negative active materials from the monoplates.

Rowlette, John J.↗

Multi-Layer Insulation Debris Sightings on Orbit

I would like to discuss a topic that has affected many previous white-light coronagraphs as well as the HI1 instruments on STEREO. By design, all of these instruments are extremely sensitive to very faint sources including, unfortunately, those generated by scattering from flakes of multi-layer insulation (MLI) that has been shed by the spacecraft. We will describe a rich history of these MLI debris sightings, and we note that engineering considerations are required to minimize these deleterious effects in the future.

SaintCyr, Chris↗

Alkali Silicate Vehicle Forms Durable, Fireproof Paint

The problem: To develop a paint for use on satellites or space vehicles that exhibits high resistance to cracking, peeling, or flaking when subjected to a wide range of temperatures. Organic coatings will partially meet the required specifications but have the inherent disadvantage of combustibility. Alkali-silicate binders, used in some industrial coatings and adhesives, show evidence of forming a fireproof paint, but the problem of high surface-tension, a characteristic of alkali silicates, has not been resolved. The solution: Use of a suitable non-ionic wetting agent combined with a paint incorporating alkali silicate as the binder.

Schutt, John B.↗

Aerogels for Thermal Insulation of Thermoelectric Devices

Silica aerogels have been shown to be attractive for use as thermal-insulation materials for thermoelectric devices. It is desirable to thermally insulate the legs of thermoelectric devices to suppress lateral heat leaks that degrade thermal efficiency. Aerogels offer not only high thermal- insulation effectiveness, but also a combination of other properties that are especially advantageous in thermoelectric- device applications. Aerogels are synthesized by means of sol-gel chemistry, which is ideal for casting insulation into place. As the scale of the devices to be insulated decreases, the castability from liquid solutions becomes increasingly advantageous: By virtue of castability, aerogel insulation can be made to encapsulate devices having any size from macroscopic down to nanoscopic and possibly having complex, three-dimensional shapes. Castable aerogels can permeate voids having characteristic dimensions as small as nanometers. Hence, practically all the void space surrounding the legs of thermoelectric devices could be filled with aerogel insulation, making the insulation highly effective. Because aerogels have the lowest densities of any known solid materials, they would add very little mass to the encapsulated devices. The thermal-conductivity values of aerogels are among the lowest reported for any material, even after taking account of the contributions of convection and radiation (in addition to true thermal conduction) to overall effective thermal conductivities. Even in ambient air, the contribution of convection to effective overall thermal conductivity of an aerogel is extremely low because of the highly tortuous nature of the flow paths through the porous aerogel structure. For applications that involve operating temperatures high enough to give rise to significant amounts of infrared radiation, opacifiers could be added to aerogels to reduce the radiative contributions to overall effective thermal conductivities. One example of an opacifier is carbon black, which absorbs infrared radiation. Another example of an opacifier is micron- sized metal flakes, which reflect infrared radiation. Encapsulation in cast aerogel insulation also can help prolong the operational lifetimes of thermoelectric devices that must operate in vacuum and that contain SiGe or such advanced skutterudite thermoelectric materials as CoSb3 and CeFe3.5Co0.5Sb12. The primary cause of deterioration of most thermoelectric materials is thermal decomposition or sublimation (e.g., sublimation of Sb from CoSb3) at typical high operating temperatures. Aerogel present near the surface of CoSb3 can impede the outward transport of Sb vapor by establishing a highly localized, equilibrium Sb vapor atmosphere at the surface of the CoSb3.

Sakamoto, Jeffrey↗

Corrosion-Prevention Capabilities of a Water-Borne, Silicone-Based, Primerless Coating

Comparative tests have been performed to evaluate the corrosion-prevention capabilities of an experimental paint of the type described in Water-Borne, Silicone-Based, Primerless Paints, NASA Tech Briefs, Vol. 26, No. 11 (November 2002), page 30. To recapitulate: these paints contain relatively small amounts of volatile organic solvents and were developed as substitutes for traditional anticorrosion paints that contain large amounts of such solvents. An additional desirable feature of these paints is that they can be applied without need for prior application of primers to ensure adhesion. The test specimens included panels of cold-rolled steel, stainless steel 316, and aluminum 2024-T3. Some panels of each of these alloys were left bare and some were coated with the experimental water-borne, silicone-based, primerless paint. In addition, some panels of aluminum 2024-T3 and some panels of a fourth alloy (stainless steel 304) were coated with a commercial solvent-borne paint containing aluminum and zinc flakes in a nitrile rubber matrix. In the tests, the specimens were immersed in an aerated 3.5-weight-percent aqueous solution of NaCl for 168 hours. At intervals of 24 hours, the specimens were characterized by electrochemical impedance spectroscopy (EIS) and measurements of corrosion potentials. The specimens were also observed visually. As indicated by photographs of specimens taken after the 168-hour immersion (see figure), the experimental primerless silicone paint was effective in preventing corrosion of stainless steel 316, but failed to protect aluminum 2024-T3 and cold-rolled steel. The degree of failure was greater in the case of the cold-rolled steel. On the basis of visual observations, EIS, and corrosion- potential measurements, it was concluded that the commercial aluminum and zinc-filled nitrile rubber coating affords superior corrosion protection to aluminum 2024-T3 and is somewhat less effective in protecting stainless steel 304.

Calle, Luz Marina↗

Remediation Technologies Eliminate Contaminants

All research and development has a story behind it, says Jacqueline Quinn, environmental engineer at Kennedy Space Center. For Quinn, one such story begins with the Saturn 1B launch stand at Kennedy and ends with a unique solution to a challenging environmental problem. Used in a number of Apollo missions and during the Skylab program, the Saturn 1B launch stand was dismantled following the transition to the Space Shuttle Program and stored in an open field at Kennedy. Decades later, the Center s Environmental Program Office discovered evidence of chemicals called polychlorinated biphenyls (PCBs) in the field s soil. The findings were puzzling since PCBs a toxin classified as a probable carcinogen by the Environmental Protection Agency (EPA) have been banned in the United States since 1979. Before the ban, PCBs were commonly used in transformer oils that leached into the ground when the oils were changed out and dumped near transformer sites, but there were no electrical transformers near the dismantled stand. It soon became apparent that the source of the PCBs was the launch stand itself. Prior to the ban, PCBs were used extensively in paints to add elasticity and other desirable characteristics. The PCB-laden paint on the Saturn 1B launch stand was flaking off into the field s soil. Nobody knew there were PCBs in the paint, says Quinn, noting that the ingredient was not monitored carefully when it was in use in 1960s. In fact, she says, the U.S. EPA was not even established until 1970, a year after Neil Armstrong first set foot on the Moon. Nobody knew any better at the time, Quinn says, but today, we have the responsibility to return any natural environmental media to as close to pristine a condition as possible. Quinn, fellow engineer Kathleen Loftin, and other Kennedy colleagues already had experience developing unprecedented solutions for environmental contamination; the team invented the emulsified zero-valent iron (EZVI) technology to safely treat groundwater tainted by chlorinated solvents once used to clean rocket engine components. The award-winning innovation (Spinoff 2010) is now NASA s most licensed technology to date. PCBs in paint presented a new challenge. Removing the launch stand for recycling proved a difficult operation; the toxic paint had to be fully stripped from the steel structure, a lengthy and costly process that required the stripped paint to be treated before disposal. Noting the lack of efficient, environmentally friendly options for dealing with PCBs, Quinn and her colleagues developed the Activated Metal Treatment System (AMTS). AMTS is a paste consisting of a solvent solution containing microscale particles of activated zero-valent metal. When applied to a painted surface, the paste extracts and degrades the PCBs into benign byproducts while leaving the paint on the structure. This provides a superior alternative to other methods for PCB remediation, such as stripping the paint or incinerating the structure, which prevents reuse and can release volatized PCBs into the air. Since its development, AMTS has proven to be a valuable solution for removing PCBs from paint, caulking, and various insulation and filler materials in older buildings, naval ships, and former munitions facilities where the presence of PCBs interferes with methods for removing trace explosive materials. Miles of potentially toxic caulking join sections of runways at airports. Any of these materials installed before 1979 potentially contain PCBs, Quinn says. "This is not just a NASA problem," she says. "It s a global problem."

Source record↗

Electrochemical Ultracapacitors Using Graphitic Nanostacks

Electrochemical ultracapacitors (ECs) have been developed using graphitic nanostacks as the electrode material. The advantages of this technology will be the reduction of device size due to superior power densities and relative powers compared to traditional activated carbon electrodes. External testing showed that these materials display reduced discharge response times compared to state-of-the-art materials. Such applications are advantageous for pulsed power applications such as burst communications (satellites, cell phones), electromechanical actuators, and battery load leveling in electric vehicles. These carbon nanostructures are highly conductive and offer an ordered mesopore network. These attributes will provide more complete electrolyte wetting, and faster release of stored charge compared to activated carbon. Electrochemical capacitor (EC) electrode materials were developed using commercially available nanomaterials and modifying them to exploit their energy storage properties. These materials would be an improvement over current ECs that employ activated carbon as the electrode material. Commercially available graphite nanofibers (GNFs) are used as precursor materials for the synthesis of graphitic nanostacks (GNSs). These materials offer much greater surface area than graphite flakes. Additionally, these materials offer a superior electrical conductivity and a greater average pore size compared to activated carbon electrodes. The state of the art in EC development uses activated carbon (AC) as the electrode material. AC has a high surface area, but its small average pore size inhibits electrolyte ingress/egress. Additionally, AC has a higher resistivity, which generates parasitic heating in high-power applications. This work focuses on fabricating EC from carbon that has a very different structure by increasing the surface area of the GNF by intercalation or exfoliation of the graphitic basal planes. Additionally, various functionalities to the GNS surface will be added that can exhibit pseudocapacitance. This pseudocapacitance exhibits faradaic (charge transfer) properties that can further increase the overall relative and volumetric capacitance of the material. A process is also proposed to use GNF as a precursor material to fabricate GNS that will be used as EC electrodes. This results in much better electrical conductivity than activated carbon. This is advantageous for high-pulsed-power applications to reduce parasitic heating. Larger average pore size allows more complete electrolyte wetting (faster charge transfer kinetics). These properties contribute to a lowered equivalent series resistance (ESR), increased specific power, shorter charging times, and decreased parasitic heating. The high density of basal plane edges provides nucleation sites for activation (addition of hydrophilic functional groups) that facilitate electrolyte wetting, and will contribute to pseudocapacitance.

Marotta, Christopher↗

Development of an Indexing Media Filtration System for Long Duration Space Missions

The effective maintenance of air quality aboard spacecraft cabins will be vital to future human exploration missions. A key component will be the air cleaning filtration system which will need to remove a broad size range of particles including skin flakes, hair and clothing fibers, other biological matter, and particulate matter derived from material and equipment wear. In addition, during surface missions any extraterrestrial planetary dust, including dust generated by near-by ISRU equipment, which is tracked into the habitat will also need to be managed by the filtration system inside the pressurized habitat compartments. An indexing media filter system is being developed to meet the demand for long-duration missions that will result in dramatic increases in filter service life and loading capacity, and will require minimal crew involvement. These features may also benefit other closed systems, such as submarines, and remote location terrestrial installations where servicing and replacement of filter units is not practical. The filtration system consists of three stages: an inertial impactor stage, an indexing media stage, and a high-efficiency filter stage, packaged in a stacked modular cartridge configuration. Each stage will target a specific range of particle sizes that optimize the filtration and regeneration performance of the system. An 1/8th scale and full-scale prototype of the filter system have been fabricated and have been tested in the laboratory and reduced gravity environments that simulate conditions on spacecrafts, landers and habitats. Results from recent laboratory and reducegravity flight tests data will be presented.

Filtration↗

Fine-Grained Targets for Laser Synthesis of Carbon Nanotubes

A mechanically robust, binder-free, inexpensive target for laser synthesis of carbon nanotubes and a method for making same, comprising the steps of mixing prismatic edge natural flake graphite with a metal powder catalyst and pressing the graphite and metal powder mixture into a mold having a desired target shape.

Smith, Michael W.↗

Monolayer Graphene Bolometer as a Sensitive Far-IR Detector

In this paper we give a detailed analysis of the expected sensitivity and operating conditions in the power detection mode of a hot-electron bolometer (HEB) made from a few micro m(sup 2) of monolayer graphene (MLG) flake which can be embedded into either a planar antenna or waveguide circuit via NbN (or NbTiN) superconducting contacts with critical temperature approx. 14 K. Recent data on the strength of the electron-phonon coupling are used in the present analysis and the contribution of the readout noise to the Noise Equivalent Power (NEP) is explicitly computed. The readout scheme utilizes Johnson Noise Thermometry (JNT) allowing for Frequency-Domain Multiplexing (FDM) using narrowband filter coupling of the HEBs. In general, the filter bandwidth and the summing amplifier noise have a significant effect on the overall system sensitivity.

noise thermometry↗

AZ-2000-IECW and StaMet Black Kapton Options for Solar Probe Plus MAG Sensor MLI Kevlar/Polyimide Shells

AZ-2000-IECW white paint and StaMet black Kapton have been evaluated for the Kevlar/polyimide shells that enclose the Solar Probe Plus Magnetometer (MAG) sensors and multilayer insulation. Flight qualification testing on AZ-2000-IECW painted Kevlar/polyimide laminate was completed at Goddard Space Flight Center. This paint potentially meets all the requirements. However, it has no flight heritage. StaMet is hotter in the sun, and is specular. The results of the MAG thermal balance test show StaMet meets the thermal requirement and heater power budget. The mission prefers to fly StaMet after evaluating the risks of AZ-2000-IECW flaking and glint from StaMet to the Star Trackers.

AZ-2000-IECW; StaMet Black Kapton; Kevlar/Polyimid↗

Fine-Grained Targets for Laser Synthesis of Carbon Nanotubes

A mechanically robust, binder-free, inexpensive target for laser synthesis of carbon nanotubes and a method for making same, comprising the steps of mixing prismatic edge natural flake graphite with a metal powder catalyst and pressing the graphite and metal powder mixture into a mold having a desired target shape.

Smith, Michael W.↗

Active and Passive 3D Vector Radiative Transfer with Preferentially-Aligned Ice Particles

For the purposes of interpreting active (radar) and passive (radiometer) microwave and millimeter wave remote sensing data, we have constructed a consistent radiative transfer modeling framework to simulate the responses for arbitrary sensors with differing sensing geometries and hardware configurations. As part of this work, we have implemented a recent method for calculating the electromagnetic properties of individual ice crystals and snow flakes. These calculations will allow us to exploit polarized remote sensing observations to discriminate different particles types and elucidate dynamics of cloud and precipitating systems.

Adams, Ian S.↗

Fire Induced Rock Spalls as Long-Term Traps for Ash

Severe fires accelerate rock weathering by spalling and exfoliation, creating abundant peels, flakes or spalls. In the following years, these spalls serve as physical traps which accommodate fine particles of dust, ash, organic matter, etc. We searched for traces of ash trapped under the spalls, after four major fires: 1989, 2005, 2010 and 2015 in Israel. Samples were collected beneath the spalls that formed on the rock outcrops, and in the immediate vicinity above and below them. Three laboratory analyses were performed: pH, EC and color. Five mineral/organic compounds were measured across the Mid-Infrared (MIR) spectral region at diffuse reflectance infrared Fourier transform mode: Hydroxylapatite (HAp), charcoal, organic carbon, montmorillonite and kaolinite. Several statistical analyses were performed: MANOVA, PCA and silhouette analysis on K-means clustering. The results show evidence of ash trapped under the spalls formed during the 2005 and 2010 fires, 6 to 11 years after the fires. Charcoal presence is evident, as well as increased amounts of HAp and organic carbon. In the exposed soil above or below the burned rock outcrop, these values are lower. Negligible amounts of ash were measured 27 years after the fire. In the 2015 burned outcrop, large amounts of charcoal were found above and below the outcrop, but not under the spalls. It seems that on the carbonate slopes of Israel and under Mediterranean climate, the time required for spalls to begin functioning as traps is longer than one rainy season, while ash traces are preserved in these traps for a period of two-three decades.

ash↗

Observations of Non-Spherical, Graphite-Epoxy Projectiles Impacting a Thermally-Insulated, Double-Wall Shield

The DebriSat hypervelocity impact experiment, performed at the Arnold Engineering Development Center (U.S.A.F. Arnold Air Force Base), is intended to update the catastrophic break-up models for modern satellites. To this end, the DebrisSat was built with many modern materials including structural panels of carbon-fiber, reinforced polymer (CFRP). Subsequent to the experiment, fragments of the DebrisSat have been extracted from porous, catcher panels used to gather the debris from the impact event. Thus far, one of the key observations from the collected fragments is that CFRP represents a large fraction of the fragments and that these fragments tend to be thin, flake-like structures or long, needle-like structures; whereas, debris with nearly equal dimensions is less prevalent. As current ballistic-limit models are all developed based upon spherical impacting particles, the experiment has pointed to a missing component in the current approach that must be considered. To begin to understand the implications of this observation, simulations like those shown in Fig. 1 have been performed using cylindrical structures at a representative orbital speed into an externally-insulated, double-wall shield that is representative of shielding of International-Space-Station-visiting vehicles. These simulations have been performed for normal impacts to the surface with three different angles-of-attack (AOA) to capture the effect on the shield performance. This paper documents the simulated shield and the models developed to study the effect of non-spherical fragments, as well as, derives the critical characteristics of CFRP impacting particles for the selected shield as shown in Fig. 2. To assist with the design of the updated debris models, this work summarizes the simulated results into a deployable form for evaluating the relative importance of fragment structures.

Miller, Joshua E.↗

The International Space Station (ISS) Port 1 (P1) External Active Thermal Control System (EATCS) Ammonia Leak

From 2011 to 2017, the crew onboard the International Space Station (ISS) was at risk of dire consequences due to an external ammonia leak. Ammonia is used in the External Active Thermal Control System (EATCS) to cool the pressurized modules and external electrical systems. Engineers at NASA's Johnson Space Center (JSC) initially detected the leak in one of two cooling loops by monitoring the system ammonia inventory decay over time. White flakes seen on High Definition (HD) cameras were also thought to be associated with the leakage but not confirmed. Initially, the leak was small enough that the ammonia inventory and system operations were not in jeopardy. However, the leak began to accelerate to the point where troubleshooting and corrective action were vital to the sustainability of the ISS. Therefore, it became imperative that the leak be located and repaired for ISS operations to continue. No tools were readily available on the ISS to locate such a leak when it was initially detected, however NASA engineers were already in the process of developing a new device for this purpose called the Robotic External Leak Locator (RELL). The RELL is a robotic instrument package with a mass spectrometer and an ion pressure gauge. Initial checkout operations with RELL happened to coincide with the increasing leak, and ammonia vapors were measured around the P1 EATCS Radiator #3 flexible jumper hoses. The leak stopped after the radiator and its flexible hoses were remotely isolated from the loop and the ammonia from the isolated segment was vented to space. Astronauts conducted a spacewalk that successfully removed the hoses, which were returned to ground for further investigation. The purpose of this paper is to review the leak detection and isolation efforts, investigation results, lessons learned and the recovery plan.

Cowan, Darnell T.↗