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NASA NTRSDate not supplied

ISRU Pilot Excavator Wheel Testing in Lunar Regolith Simulant

The ISRU Pilot Excavator, or IPEx, is a robotic excavator funded by NASA’s Space Technology Mission Directorate (STMD). The Concept of Operations for IPEx involves the robot driving on the lunar surface up to 70 km at a speed of up to 30 cm/s. As such, it is critical to the mission’s success to optimize the design of the wheels for performance in lunar conditions, specifically in lunar regolith. To achieve this, an array of tests was completed to observe the effects of various wheel design choices on the driving performance of the wheels in lunar regolith simulant. In order to facilitate testing, we designed a 12” dia. configurable wheel to allow for interchangeability between various wheel formations. Two types of wheel parts were designed to be swapped: cleats, which form the tread of the wheel; and grousers, which protrude from the treads. The test variables that we considered were as follows: square vs. round wheel shape, solid vs. perforated cleats, cleat spacing, grouser height, and grouser spacing. By combining different settings of each of these test variables, ten discrete wheel designs were created and tested. The configurable test wheels were mounted on the Regolith Advanced Surface Systems Operations Robot (RASSOR) developed at NASA’s Kennedy Space Center. In our experiments, the robot was driven at a controlled speed across a prepared surface of BP-1 lunar regolith simulant. Four types of tests were conducted: circle driving, straight driving, slope driving, and drawbar pull. The driving tests were chosen to mimic a variety of conditions in which IPEx may be expected to operate, and the drawbar pull test was chosen to provide a standard of comparison with existing wheel design literature. The circle and straight driving tests were each performed at different levels: for the circle driving test, the robot was driven at a constant linear speed and three different angular speeds, while for the straight driving test, the robot was driven at three different linear speeds. The data collected from these tests included the power usage from each of the wheels, measurements of the tread patterns left in the regolith surface, and the amount of slip the wheels experienced, which was calculated using data from an OptiTrack motion capture system. From the results of these experiments, we found that certain test variables were more significant than others in determining performance for each type of test, and no single wheel design clearly outperformed the others in all areas. The details of our findings will be discussed further in this paper. This data will be utilized to inform the design of the wheels for IPEx and can provide a basis for the design of wheels for future lunar terrain vehicles.

RASSOR↗
NASA NTRSDate not supplied

Developments of Bosch Process Architectures for ISRU Terrestrial Applications

To effectively realize NASA’s goals of a sustainable presence on the Moon and be-yond, In-Situ Resource Utilization (ISRU) must be leveraged. To reduce launch mass for space missions, commodities such as oxygen and carbon can be produced in-situ. Oxygen can be used for life support and as a propellant, and carbon can be used for battery production, filtration, additive manufacturing, and steel casting. Carbon is a required reactant in the carbothermal reduction process, a leading candidate for oxygen production on the lunar surface. To pro-duce these consumables, the Carbon Utilization Technology for Lunar and Atmospheric Systems (CUTLAS) project is developing architectures that leverage the Bosch process. The Bosch process re-acts CO 2 and H 2 to produce carbon powder and water, which can then be electrolyzed, leaving O 2 and recycled H 2 . This process is also applicable to carbon dioxide emissions on Earth.

Carbon capture↗
NASA NTRSDate not supplied

ISRU Pilot Excavator (IPEx) Technology Readiness Level 5 Design Overview

This paper details the mechanical and mechatronic design of the Technology Readiness Level (TRL)-5 In-Situ Resource Utilization (ISRU) Pilot Excavator (IPEx). IPEx is a robotic excavator designed for a technology demonstration of regolith mining in the lunar south -pole region. The novel design uses pairs of counter-acting excavation tools called bucket drums, that dig at the same time in opposing directions to reduce the reaction force needed, thereby enabling mining with a small, low-mass, robotic system. IPEx builds on the prior work of the Regolith Advanced Surface Systems Operations Robot (RASSOR), which is the TRL-4 implementation of this concept. The TRL-5 IPEx subsystems that are discussed in this paper include: Regolith Delivery Subsystem (RDS), Mobility Subsystem (MS), Cameras and Dust Mitigation Subsystem (CDMS), and Thermal Control Subsystem (TCS). Each subsystem is described in detail with rationale for design selections. Dust tolerance is a key feature for IPEx and this paper details a thermal control system with an actuated radiator cover and phase change material as well as camera modules with removable electrodynamic dust shields (EDS). Additional components such as actuators, wheels, and bucket drums are discussed in detail. Due to their complexity, the avionics and software subsystems will be discussed in a separate publication.

RASSOR↗
NASA NTRS2025

CFD Validation and Scaling of a Condenser Used in an ISRU Propellant Production System

This work develops a Computational Fluid Dynamics (CFD) model of a Commercial-Off-The-Shelf (COTS) condenser used for ground-based testing of an In-Situ Resource Utilization (ISRU) propellant production system. STAR-CCM+ was used to simulate water condensing through the condenser downstream of a methanation reactor. The computational data of the digital model is validated with test cases using nitrogen and water in ambient conditions. After validation with the test data, the digital model can be used to predict scale at higher production targets. The StarCCM+ simulation of the digital model shows good agreement with the test data provided. From the simulation, the condensation rate calculated was 18.3 g/hr and the process gas mass flow rate was 709.2 g/hr. The test data measured an average 16.9 g/hr condensation rate and 693.6 g/hr process gas mass flow rate. The simulation shows a 7.3% error in the water condensation and 2.2% error in the process gas at the outlet.

Condenser↗
NASA NTRS2025

CFD Validation of a Methanation Reactor With Cooling Jacket Used in an ISRU Propellant Production System

A digital model of an OxEon Energy methanation reactor (with a cooling jacket) planned for use in a NASA designed In-Situ Resource Utilization (ISRU) propellant production system was developed by the UTEP Aerospace Center using STAR-CCM+ software, a Siemens Computational Fluid Dynamics (CFD) package. The reactor digital model created includes two primary components: (i) a cooling jacket that maintains the required reactor chamber surface temperature and (ii) a reactor core chamber where the exothermic methanation reactions occur. The StarCCM+ digital model has two objectives: (i) maintain the surface temperature of the reactor below a set value so that the extra heat accumulation does not melt or crack the chamber, and (ii) produce the desired amount of methane (CH4) according to test cases completed by OxEon Energy for NASA JSC. The computational digital model was validated with the test data enabling the cooling jacket scale to be predicted based on the reactor's operating temperature. The StarCCM+ simulation of the digital model shows a good agreement with the cooling jacket performance and the CH4 production. One test case for the cooling jacket maintained the reactor wall temperature around 310 °C was validated and the reactor produced 185 g/hr CH 4 .

ISRU↗
NASA NTRS1995

Human Lunar Mission Capabilities Using SSTO, ISRU and LOX-Augmented NTR Technologies: A Preliminary Assessment

The feasibility of conducting human missions to the Moon is examined assuming the use of three 'high leverage' technologies: (1) a single-stage-to-orbit (SSTO) launch vehicle, (2) 'in-situ' resource utilization (ISRU)--specifically 'lunar-derived' liquid oxygen (LUNOX), and (3) LOX-augmented nuclear thermal rocket (LANTR) propulsion. Lunar transportation system elements consisting of a LANTR-powered lunar transfer vehicle (LTV) and a chemical propulsion lunar landing/Earth return vehicle (LERV) are configured to fit within the 'compact' dimensions of the SSTO cargo bay (diameter: 4.6 m/length: 9.0 m) while satisfying an initial mass in low Earth orbit (IMLEO) limit of approximately 60 t (3 SSTO launches). Using approximately 8 t of LUNOX to 'reoxidize' the LERV for a 'direct return' flight to Earth reduces its size and mass allowing delivery to LEO on a single 20 t SSTO launch. Similarly, the LANTR engine's ability to operate at any oxygen/ hydrogen mixture ratio from 0 to 7 with high specific impulse (approximately 940 to 515 s) is exploited to reduce hydrogen tank volume, thereby improving packaging of the LANTR LTV's 'propulsion' and 'propellant modules'. Expendable and reusable, piloted and cargo missions and vehicle designs are presented along with estimates of LUNOX production required to support the different mission modes. Concluding remarks address the issue of lunar transportation system costs from the launch vehicle perspective.

Borowski, Stanley K.↗
NASA NTRS1997

In Situ Resource Utilization (ISRU) Technical Interchange Meeting

This volume contains abstracts that have been accepted for presentation at the In Situ Resource Utilization (ISRU) Technical Interchange Meeting, February 4-5, 1997, at the Lunar and Planetary Institute, Houston, Texas. Abstracts are arranged in order of presentation at the meetings, with corresponding page numbers shown in the enclosed agenda. Logistics, administration, and publication support for this meeting were provided by the staff of the Publications and Program Services Department at the Lunar and Planetary Institute.

Source record↗
NASA NTRS1997

In Situ Resource Utilization (ISRU II) Technical Interchange Meeting

This volume contains extended abstracts that have been accepted for presentation at the In Situ Resource Utilization (ISRU II) Technical Interchange Meeting, November 18-19, 1997, at the Lunar and Planetary Institute, Houston, Texas. Included are topics which include: Extraterrestrial resources, in situ propellant production, sampling of planetary surfaces, oxygen production, water vapor extraction from the Martian atmosphere, gas generation, cryogenic refrigeration, and propellant transport and storage.

David Kaplan↗
NASA NTRS1999

In Situ Resource Utilization (ISRU 3) Technical Interchange Meeting: Abstracts

This volume contains abstracts that have been accepted for presentation at the In Situ Resource Utilization (ISRU III) Technical Interchange Meeting, February 11-12, 1999, hosted by the Lockheed Martin Astronautics Waterton Facility, Denver, Colorado. Administration and publication support for this meeting were provided by the staff of the Publications and Program Services Department at the Lunar and Planetary Institute.

Source record↗
NASA NTRS1999

Initial Test Firing Results for Solid CO/GOX Cryogenic Hybrid Rocket Engine for Mars ISRU Propulsion Applications

ORBITEC is developing methods for producing, testing, and utilizing Mars-based ISRU fuel/oxidizer combinations to support low cost, planetary surface and flight propulsion and power systems. When humans explore Mars we will need to use in situ resources that are available, such as: energy (solar); gases or liquids for life support, ground transportation, and flight to and from other surface locations and Earth; and materials for shielding and building habitats and infrastructure. Probably the easiest use of Martian resources to reduce the cost of human exploration activities is the use of the carbon and oxygen readily available from the CO2 in the Mars atmosphere. ORBITEC has conducted preliminary R&D that will eventually allow us to reliably use these resources. ORBITEC is focusing on the innovative use of solid CO as a fuel. A new advanced cryogenic hybrid rocket propulsion system is suggested that will offer advantages over LCO/LOX propulsion, making it the best option for a Mars sample return vehicle and other flight vehicles. This technology could also greatly support logistics and base operations by providing a reliable and simple way to store solar or nuclear generated energy in the form of chemical energy that can be used for ground transportation (rovers/land vehicles) and planetary surface power generators. This paper describes the overall concept and the test results of the first ever solid carbon monoxide/oxygen rocket engine firing.

Rice, Eric E.↗
NASA NTRS2000

Performance of Adsorption - Based CO2 Acquisition Hardware for Mars ISRU

Chemical processing of the dusty, low-pressure Martian atmosphere typically requires conditioning and compression of the gases as first steps. A temperature-swing adsorption process can perform these tasks using nearly solid-state hardware and with relatively low power consumption compared to alternative processes. In addition, the process can separate the atmospheric constituents, producing both pressurized CO2 and a buffer gas mixture of nitrogen and argon. To date we have developed and tested adsorption compressors at scales appropriate for the near-term robotic missions that will lead the way to ISRU-based human exploration missions. In this talk we describe the characteristics, testing, and performance of these devices. We also discuss scale-up issues associated with meeting the processing demands of sample return and human missions.

Finn, John E.↗
NASA NTRS2004

Separation of Carbon Monoxide and Carbon Dioxide for Mars ISRU

The atmosphere of Mars has many resources that can be processed to produce things such as oxygen, fuel, buffer gas, and water for support of human exploration missions. Successful manipulation of these resources is crucial for safe, cost-effective, and self-sufficient long-term human exploration of Mars. In our research, we are developing enabling technologies that require fundamental knowledge of adsorptive gas storage and separation processes. In particular, we are designing and constructing an innovative, low mass, low power separation device to recover carbon dioxide and carbon monoxide for Mars ISRU (in-situ resource utilization). The technology has broad implications for gas storage and separations for gas-solid systems that are ideally suited for reduced gravitational environments. This paper describes our separation process design and experimental procedures and reports results for the separation of CO2 and CO by a four-step adsorption cycle.

Walton, Krista S.↗
NASA NTRS2004

Robotic Subsurface Analyzer and Sample Handler for Resource Reconnaissance and Preliminary Site Assessment for ISRU Activities at the Lunar Cold Traps

Since the 1960s, claims have been made that water ice deposits should exist in permanently shadowed craters near both lunar poles. Recent interpretations of data from the Lunar Prospector-Neutron Spectrometer (LP- NS) confirm that significant concentrations of hydrogen exist, probably in the form of water ice, in the permanently shadowed polar cold traps. Yet, due to the large spatial resolution (45-60 Ian) of the LP-NS measurements relative to these shadowed craters (approx.5-25 km), these data offer little certainty regarding the precise location, form or distribution of these deposits. Even less is known about how such deposits of water ice might effect lunar regolith physical properties relevant to mining, excavation, water extraction and construction. These uncertainties will need to be addressed in order to validate fundamental lunar In Situ Resource Utilization (ISRU) precepts by 2011. Given the importance of the in situ utilization of water and other resources to the future of space exploration a need arises for the advanced deployment of a robotic and reconfigurable system for physical properties and resource reconnaissance. Based on a collection of high-TRL. designs, the Subsurface Analyzer and Sample Handler (SASH) addresses these needs, particularly determining the location and form of water ice and the physical properties of regolith. SASH would be capable of: (1) subsurface access via drilling, on the order of 3-10 meters into both competent targets (ice, rock) and regolith, (2) down-hole analysis through drill string embedded instrumentation and sensors (Neutron Spectrometer and Microscopic Imager), enabling water ice identification and physical properties measurements; (3) core and unconsolidated sample acquisition from rock and regolith; (4) sample handling and processing, with minimized contamination, sample containerization and delivery to a modular instrument payload. This system would be designed with three mission enabling goals, including: (1) a self-contained, low power, low mass, "black box'' configuration for operations from a lander, various classes of rovers or a surface-based platform with human assistance or robotic anchoring mechanisms; (2) reconfigurable and scalable sample handling for delivery to various types of instrumentation, depending on mission requirements; and (3) the use of advanced automation control and diagnostic techniques that will afford local human deployed, remote teleoperation and fully autonomous intelligent operations. Though a great deal of technology has been advanced toward these objectives, the SASH system faces significant design challenges, including the low gravity environment, various levels of autonomy in operations, radiation exposure, dust contamination, and temperature extremes and deltas. Significant input from the scientific and engineering communities, as well as a significant environmental testing program, will be required to guide the design process.

Gorevan, S. P.↗
NASA NTRS2005

Lunar Contour Crafting: A Novel Technique for ISRU-Based Habitat Development

1. Habitat Structures at MSFC is one element of the In-Situ Fabrication and Repair (ISFR) Program: ISFR develops technologies for fabrication, repair and recycling of tools, parts, and habitats/structures using in-situ resources. ISRU - based habitat structures are considered Class III. 2. Habitat Structure Purpose: Develop Lunar and/or Martian habitat structures for manned missions that maximize the use of in-situ resources to address the following agency topics: bioastronautics critical path roadmap; strategic technical challenges defined in H&RT formulation plan: margins and redundancy; modularity, robotic network, space resource utilization; autonomy, affordable logistics pre-positioning.

Khoshnevis, Behrokh↗
NASA NTRS2005

Plasma Assisted ISRU at Mars

NASA's exploration goals for Mars and Beyond will require new power systems and in situ resource utilization (ISRU) technologies. Regenerative aerobraking may offer a revolutionary approach for in situ power generation and oxygen harvesting during these exploration missions. In theory, power and oxygen can be collected during aerobraking and stored for later use in orbit or on the planet. This technology would capture energy and oxygen from the plasma field that occurs naturally during hypersonic entry using well understood principles of magnetohydrodynamics and oxygen filtration. This innovative approach generates resources upon arrival at the operational site, and thus greatly differs from the traditional approach of taking everything you need with you from Earth. Fundamental analysis, computational fluid dynamics, and some testing of experimental hardware have established the basic feasibility of generating power during a Mars entry. Oxygen filtration at conditions consistent with spacecraft entry parameters at Mars has been studied to a lesser extent. Other uses of the MHD power are presented. This paper illustrates how some features of regenerative aerobraking may be applied to support human and robotic missions at Mars.

Moses, Robert W.↗
NASA NTRS2005

Formation of Nanophase Iron in Lunar Soil Simulant for Use in ISRU Studies

For the prospective return of humans to the Moon and the extensive amount of premonitory studies necessary, large quantities of lunar soil simulants are required, for a myriad of purposes from construction/engineering purposes all the way to medical testing of its effects from ingestion by humans. And there is only a limited and precious quantity of lunar soil available on Earth (i.e., Apollo soils) - therefore, the immediate need for lunar soil simulants. Since the Apollo era, there have been several simulants; of these JSC-1 (Johnson Space Center) and MLS-1 (Minnesota Lunar Simulant) have been the most widely used. JSC-1 was produced from glassy volcanic tuff in order to approximate lunar soil geotechnical properties; whereas, MLS-1 approximates the chemistry of Apollo 11 high-Ti soil, 10084. Stocks of both simulants are depleted, but JSC-1 has recently gone back into production. The lunar soil simulant workshop, held at Marshall Space Flight Center in January 2005, identified the need to make new simulants for the special properties of lunar soil, such as nanophase iron (np-Fe(sup 0). Hill et al. (2005, this volume) showed the important role of microscale Fe(sup 0) in microwave processing of the lunar soil simulants JSC-1 and MLS-1. Lunar soil is formed by space weathering of lunar rocks (e.g., micrometeorite impact, cosmic particle bombardment). Glass generated during micrometeorite impact cements rock and mineral fragments together to form aggregates called agglutinates, and also produces vapor that is deposited and coats soil grains. Taylor et al. (2001) showed that the relative amount of impact glass in lunar soil increases with decreasing grain size and is the most abundant component in lunar dust (less than 20 micrometer fraction). Notably, the magnetic susceptibility of lunar soil also increases with the decreasing grain size, as a function of the amount of nanophase-sized Fe(sup 0) in impact-melt generated glass. Keller et al. (1997, 1999) also discovered the presence of abundant np-Fe(sup 0) particles in the glass patinas coating most soil particles. Therefore, the correlation of glass content and magnetic susceptibility can be explained by the presence of the np-Feo particles in glass: small particles contain relatively more np-Fe(sup 0) as glass coatings because the surface area versus mass ratio of the grain size is so increased. The magnetic properties of lunar soil are important in dust mitigation on the Moon (Taylor et al. 2005). Thus material simulating this property is important for testing mitigation methods using electromagnetic field. This np- Fe(sup 0) also produces a unique energy coupling to normal microwaves, such as present in kitchen microwave ovens. Effectively, a portion of lunar soil placed in a normal 2.45 GHz oven will melt at greater than 1200 C before your tea will boil at 100 C, a startling and new discovery reported by Taylor and Meek (2004, 2005). Several methods have been investigated in attempts to make nanophase-sized Feo dispersed within silicate glass; like in the lunar glass. We have been successful in synthesizing such a product and continue to improve on our recipe. We have performed extensive experimentation on this subject to date. Ultimately it will probably be necessary to add this np-Fe(sup 0) bearing silicate glass to lunar soil stimulant, like JSC-1, to actually produce the desired magnetic and microwave coupling properties for use in appropriate ISRU experimentation.

Liu, Yang↗
NASA NTRS2007

Vacuum Pyrolysis and Related ISRU Techniques

A number of ISRU-related techniques have been developed at NASA Goddard Space Flight Center. The focus of the team has been on development of the vacuum pyrolysis technique for the production of oxygen from the lunar regolith. However, a number of related techniques have also been developed, including solar concentration, solar heating of regolith, resistive heating of regolith, sintering, regolith boiling, process modeling, parts manufacturing, and instrumentation development. An initial prototype system was developed to vaporize regolith simulants using a approx. l square meter Fresnel lens. This system was successfully used to vaporize quantities of approx. lg, and both mass spectroscopy of the gasses produced and Scanning Electron Microscopy (SEM) of the slag were done to show that oxygen was produced. Subsequent tests have demonstrated the use of a larger system With a 3.8m diameter reflective mirror to vaporize the regolith. These results and modeling of the vacuum pyrolysis reaction have indicated that the vaporization of the oxides in the regolith will occur at lower temperature for stronger vacuums. The chemical modeling was validated by testing of a resistive heating system that vaporized quantities of approx. 10g of MLS-1A. This system was also used to demonstrate the sintering of regolith simulants at reduced temperatures in high vacuum. This reduction in the required temperature prompted the development of a small-scale resistive heating system for application as a scientific instrument as well as a proof-of principle experiment for oxygen production.

Cardiff, Eric H.↗