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NASA NTRS1993

Effect of hydrogen exposure on a Cu-8 Cr-4 Nb alloy

The advanced regeneratively cooled rocket thrust chamber may require new materials to achieve long life and improved performance. Current materials such as NARloy-Z (Cu-3 wt. percent Ag-0.5 wt. percent Zr), while highly conductive, do not have sufficient high temperature strength and creep resistance to meet the projected needs of advanced rocket motors. A Cu-8 at. percent Cr-4 at. percent Nb (Cu-8 Cr-4 Nb) alloy has been identified as a promising material for this application. However, hydrogen embrittlement is a concern given the presence of high pressure, high temperature hydrogen in regeneratively cooled rocket motors. Thermodynamic analysis of the reaction between Cr-rich Cr2Nb and H2 showed that there is a possibility of reaction at temperatures up to 323 K in a 35 MPa H2 environment. Above 323 K the pressure necessary to achieve reaction rapidly increased beyond the range experienced in rocket motors. Tensile specimens exposed in 34.5 MPa H2 at room temperatures and during cycling to 705 C did not show any degradation of properties. No evidence of reaction was observed for Cr2Nb precipitate observed on the fracture surfaces. Based on these results the Cu-8 Cr-4 Nb alloy was judged to be sufficiently stable for use in rocket motors.

David L Ellis↗

NASA NTRS2009

Lunar Outpost Life Support Architecture Study Based on a High Mobility Exploration Scenario

As scenarios for lunar surface exploration and habitation continue to evolve within NASA s Constellation program, so must studies of optimal life support system architectures and technologies. This paper presents results of a life support architecture study based on a 2009 NASA scenario known as Scenario 12. Scenario 12 represents a consolidation of ideas from earlier NASA scenarios and includes an outpost near the Lunar South Pole comprised of three larger fixed surface elements and four attached pressurized rovers. The scenario places a high emphasis on surface mobility, with planning assuming that all four crewmembers spend roughly 50% of the time away from the outpost on 3-14 day excursions in two of the pressurized rovers. Some of the larger elements can also be mobilized for longer duration excursions. This emphasis on mobility poses a significant challenge for a regenerative life support system in terms of cost-effective waste collection and resource recovery across multiple elements, including rovers with very constrained infrastructure resources. The current study considers pressurized rovers as part of a distributed outpost life support architecture in both stand-alone and integrated configurations. A range of architectures are examined reflecting different levels of closure and distributed functionality. Different lander propellant scavenging options are also considered involving either initial conversion of residual oxygen and hydrogen propellants to water or initial direct oxygen scavenging. Monte Carlo simulations are used to assess the sensitivity of results to volatile high-impact mission variables, including the quantity of residual lander propellants available for scavenging, the fraction of crew time away from the outpost on excursions, total extravehicular activity hours, and habitat leakage. Architectures are evaluated by estimating surpluses or deficits of water and oxygen per 180-day mission and differences in fixed and 10-year-total equivalent system mass (ESM) relative to a reference case. Results are presented based on current assumptions for Scenario 12 and based on Monte Carlo simulations with assumed probability distributions for the high-impact mission variables. The calculated probability of no water or oxygen resupply from Monte Carlo simulations provides a quantitative measure of system robustness that can be used for cost/benefit analyses to identify leading architecture candidates. Areas of technology improvement that are likely to have a significant impact are also suggested.

Lange, Kevin E.↗

NASA NTRS2018

Additive Manufacturing of Liquid Rocket Engine Combustion Devices: A Summary of Process Developments and Hot-Fire Testing Results

Additive Manufacturing (AM) of metals is a processing technology that has significantly matured over the last decade. For liquid propellant rocket engines, the advantages of AM for replacing conventional manufacturing of complicated and expensive metallic components and assemblies are very attractive. AM can significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing for use in liquid rocket engine component design, development, and testing since 2010. The AM technique most often used at the NASA MSFC has been powder-bed fusion or selective laser melting (SLM), although other techniques including laser directed energy deposition (DED), arc-based deposition, and laser-wire cladding techniques have also been used to develop several components. The purpose of this paper is to discuss the various internal programs at the NASA MSFC using AM to develop combustion devices hardware. To date at the NASA MSFC, combustion devices component hardware ranging in size from 100 lbf to 35,000 lbf have been designed and manufactured using SLM and deposition-based AM processes, and many of these pieces have been hot-fire tested. Combustion devices component hardware have included thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. Ongoing and future developments for combustion devices have also included design of components sized for boost-class engines. Several design and hot-fire test iterations have been completed on these subscale and larger scale components, and a summary of these results will be presented as well.

Gradl, Paul↗

NASA NTRS2011

High Power Flex-Propellant Arcjet Performance

A MW-class electrothermal arcjet based on a water-cooled, wall-stabilized, constricted arc discharge configuration was subjected to extensive performance testing using hydrogen and simulated ammonia propellants with the deliberate aim of advancing technology readiness level for potential space propulsion applications. The breadboard design incorporates alternating conductor/insulator wafers to form a discharge barrel enclosure with a 2.5-cm internal bore diameter and an overall length of approximately 1 meter. Swirling propellant flow is introduced into the barrel, and a DC arc discharge mode is established between a backplate tungsten cathode button and a downstream ringanode/ spin-coil assembly. The arc-heated propellant then enters a short mixing plenum and is accelerated through a converging-diverging graphite nozzle. This innovative design configuration differs substantially from conventional arcjet thrusters, in which the throat functions as constrictor and the expansion nozzle serves as the anode, and permits the attainment of an equilibrium sonic throat (EST) condition. During the test program, applied electrical input power was varied between 0.5-1 MW with hydrogen and simulated ammonia flow rates in the range of 4-12 g/s and 15-35 g/s, respectively. The ranges of investigated specific input energy therefore fell between 50-250 MJ/kg for hydrogen and 10-60 MJ/kg for ammonia. In both cases, observed arc efficiencies were between 40-60 percent as determined via a simple heat balance method based on electrical input power and coolant water calorimeter measurements. These experimental results were found to be in excellent agreement with theoretical chemical equilibrium predictions, thereby validating the EST assumption and enabling the utilization of standard TDK nozzle expansion analyses to reliably infer baseline thruster performance characteristics. Inferred specific impulse performance accounting for recombination kinetics during the expansion process implied nearly frozen flow in the nozzle and yielded performance ranges of 800-1100 sec for hydrogen and 400-600 sec for ammonia. Inferred thrust-to-power ratios were in the range of 30-10 lbf/MWe for hydrogen and 60-20 lbf/MWe for ammonia. Successful completion of this test series represents a fundamental milestone in the progression of high power arcjet technology, and it is hoped that the results may serve as a reliable touchstone for the future development of MW-class regeneratively-cooled flex-propellant plasma rockets.

Litchford, Ron J.↗

NASA NTRS2019

Common Power and Energy Storage Solutions to Support Lunar and Mars Surface Exploration Missions

Future human exploration missions on the moon and Mars will require a new generation of power sources to sustain crew members and leverage in-situ resources. Long-duration human missions to the lunar and Martian surface will likely include large-scale landers, crew habitats, pressurized rovers, and in-situ propellant production plants. The power demands for these surface elements, whether on the moon or Mars, will be similar starting with robotic precursor missions in the multi-kilowatt range scaling to 10s of kilowatts as the crew presence expands and local propellant production is established. While the power requirements may be similar, the vastly different environments on the two surfaces present unique challenges for power generation and storage systems. Candidate technologies to satisfy the surface power needs include deployable solar arrays, regenerative fuel cells, and small fission reactors. This paper presents strategies for power system architectures with elements that can be used on the moon and are extensible to Mars with features that make them resilient to either environment.

Mason, Lee↗

NASA NTRS1988

Oxygen electrode bifunctional electrocatalyst NiCo2O4 spinel

A significant increase in energy density may be possible if a two-unit alkaline regenerative H2-O2 fuel cell is replaced with a single-unit system that uses passive means for H2O transfer and thermal control. For this single-unit system, new electrocatalysts for the O2 electrode will be required which are not only bifunctionally active but also chemically and electrochemically stable between the voltage range of about 0.7 and 1.5 V. NiCo2O4 spinel is reported to have certain characteristics that make it useful for a study of electrode fabrication techniques. High surface area NiCo2O4 powder was fabricated into unsupported, bifunctional, PTFE-bonded, porous gas fuel cell electrodes by commercial sources using varying PTFE contents and sintering temperatures. The object of this study is to measure the bifunctional activities of these electrodes and to observe what performance differences might result from different commercial electrode fabricators. O2 evolution and O2 reduction data were obtained at 80 C (31 percent KOH). An irreversible reaction (i.e., aging) occurred during O2 evolution at potentials greater than about 1.5 V. Anodic Tafel slopes of 0.06 and 0.12 V/decade were obtained for the aged electrodes. Within the range of 15 to 25 percent, the PTFE content was not a critical parameter for optimizing the electrode for O2 evolution activity. Sintering temperatures between 300 and 340 C may be adequate but heating at 275 C may not be sufficient to properly sinter the PTFE-NiCo2O4 mixture. Electrode disintegration was observed during O2 reduction. Transport of O2 to the NiCo2O4 surface became prohibitive at greater than about -0.02 A/sq cm. Cathodic Tafel slopes of -0.6 and -0.12 V/decade were assumed for the O2 reduction process. A PTFE content of 25 percent (or greater) appears to be preferable for sintering the PTFE-NiCo2O4 mixture.

Fielder, William L.↗

NASA NTRS2016

Design, Development, and Testing of a Water Vapor Exchanger for Spacecraft Life Support Systems

Thermal and environmental control systems for future exploration spacecraft must meet challenging requirements for efficient operation and conservation of resources. Maximizing the use of regenerative systems and conserving water are critical considerations. This paper describes the design, development, and testing of an innovative water vapor exchanger (WVX) that can minimize the amount of water absorbed in, and vented from, regenerative CO2 removal systems. Key design requirements for the WVX are high air flow capacity (suitable for a crew of six), very high water recovery, and very low pressure losses. We developed fabrication and assembly methods that enable high-efficiency mass transfer in a uniform and stable array of Nafion tubes. We also developed analysis and design methods to compute mass transfer and pressure losses. We built and tested subscale units sized for flow rates of 2 and 5 cu ft/min (3.4–8.5 cu m/hr). Durability testing demonstrated that a stable core geometry was sustained over many humid/dry cycles. Pressure losses were very low (less than 0.5 in. H2O (125 Pa) total) and met requirements at prototypical flow rates. We measured water recovery efficiency across a range of flow rates and humidity levels that simulate the range of possible cabin conditions. We measured water recovery efficiencies in the range of 80 to 90%, with the best efficiency at lower flow rates and higher cabin humidity levels. We compared performance of the WVX with similar units built using an unstructured Nafion tube bundle. The WVX achieves higher water recovery efficiency with nearly an order of magnitude lower pressure drop than unstructured tube bundles. These results show that the WVX provides uniform flow through flow channels for both the humid and dry streams and can meet requirements for service on future exploration spacecraft. The WVX technology will be best suited for long-duration exploration vehicles that require regenerative CO2 removal systems while needing to conserve water.

Izenson, Michael G.↗

NASA NTRS1977

Graphical method for predicting life of a rocket thrust chamber with half-hard zirconium-copper liner and electroformed nickel closeout

A method for estimating the life of a regeneratively cooled rocket thrust chamber was developed and is based on the hot-gas wall temperature and the temperature difference between the hot-gas wall and the outside surface of the closeout. This method permits a quick estimate of the life of a thrust chamber when design changes or test-cycle variations are considered. Strain range and life are presented graphically as functions of these temperature parameters for a typical high-performance rocket thrust chamber with a half-hard zirconium-copper liner and an electroformed nickel closeout.

Kasper, H. J.↗

NASA NTRS1991

Johnson Space Center's regenerative life support systems test bed

The Regenerative Life Support System (RLSS) Test Bed at NASA's Johnson Space Center is an atmospherically closed, controlled environment facility for the evaluation of regenerative life support systems using higher plants in conjunction with physicochemical life support systems. When completed, the facility will be comprised of two large scale plant growth chambers, each with approximately 10 m(exp 2) growing area. One of the two chambers, the Variable Pressure Growth Chamber (VPGC), will be capable of operating at lower atmospheric pressures to evaluate a range of environments that may be used in Lunar or Martian habitats; the other chamber, the Ambient Pressure Growth Chamber (APGC) will operate at ambient atmospheric pressure. The root zone in each chamber will be configurable for hydroponic or solid state media systems. Research will focus on: (1) in situ resource utilization for CELSS systems, in which simulated lunar soils will be used in selected crop growth studies; (2) integration of biological and physicochemical air and water revitalization systems; (3) effect of atmospheric pressure on system performance; and (4) monitoring and control strategies.

Henninger, Donald L.↗

NASA NTRS1973

Design of thermal protection system for 8 foot HTST combustor

The combustor in the 8-foot high temperature structures tunnel at the NASA-Langley Research Center has encountered cracking over a period of 50-250 tunnel tests within a limited range of the required operating envelope. A program was conducted which analyzed the failed combustor liner hardware and determined that the mechanism of failure was vibratory fatigue. A vibration damper system using wave springs located axially between the liner T-bar and the liner support was designed as an intermediate solution to extend the life of the current two-pass regenerative air-cooled liner. The effects of liner wall thickness, cooling air passage height, stiffener ring geometry, reflective coatings, and liner material selection were investigated for these designs. Preliminary layout design arrangements including the external water-cooling system requirements, weight estimates, installation requirements and preliminary estimates of manufacturing costs were prepared for the most promissing configurations. A state-of-the-art review of thermal barrier coatings and an evaluation of reflective coatings for the gasside surface of air-cooled liners are included.

Moskowitz, S.↗

NASA NTRS1987

High temperature electrolyzer/fuel cell power cycle: Preliminary design considerations

A model of a high temperature electrolyzer/fuel cell, hydrogen/oxygen, thermally regenerative power cycle is developed and used to simulate system performance for varying system parameters. Initial estimates of system efficiency, weight, and volume are provided for a one KWe module assuming specific electrolyzer and fuel cell characteristics, both current and future. Specific interest is placed on examining the system responses to changes in device voltage versus current density operating curves, and the associated optimum operating ranges. The performance of a solar-powered, space based system in low earth orbit is examined in terms of the light-dark periods requiring storage. The storage design tradeoffs between thermal energy, electrical energy, and hydrogen/oxygen mass storage are examined. The current technology module is based on the 1000 C solid oxide electrolyzer cell and the alkaline fuel cell. The Future Technology system examines benefits involved with developing a 1800K electrolyzer operating with an advanced fuel cell.

Morehouse, Jeffrey H.↗

NASA NTRS2011

Lightweight Magnetic Cooler With a Reversible Circulator

A design of a highly efficient and lightweight space magnetic cooler has been developed that can continuously provide remote/distributed cooling at temperatures in the range of 2 K with a heat sink at about 15 K. The innovative design uses a cryogenic circulator that enables the cooler to operate at a high cycle frequency to achieve a large cooling capacity. The ability to provide remote/distributed cooling not only allows flexible integration with a payload and spacecraft, but also reduces the mass of the magnetic shields needed. The active magnetic regenerative refrigerator (AMRR) system is shown in the figure. This design mainly consists of two identical magnetic regenerators surrounded by their superconducting magnets and a reversible circulator. Each regenerator also has a heat exchanger at its warm end to reject the magnetization heat to the heat sink, and the two regenerators share a cold-end heat exchanger to absorb heat from a cooling target. The circulator controls the flow direction, which cycles in concert with the magnetic fields, to facilitate heat transfer. Helium enters the hot end of the demagnetized column, is cooled by the refrigerant, and passes into the cold-end heat exchanger to absorb heat. The helium then enters the cold end of the magnetized column, absorbing heat from the refrigerant, and enters the hot-end heat exchanger to reject the magnetization heat. The efficient heat transfer in the AMRR allows the system to operate at a relatively short cycle period to achieve a large cooling power. The key mechanical components in the magnetic cooler are the reversible circulator and the magnetic regenerators. The circulator uses non-contacting, self-acting gas bearings and clearance seals to achieve long life and vibration- free operation. There are no valves or mechanical wear in this circulator, so the reliability is predicted to be very high. The magnetic regenerator employs a structured bed configuration. The core consists of a stack of thin GGG disks alternating with thin polymer insulating films. The structured bed reduces flow resistance in the regenerator and therefore the pumping work by the cryogenic circulator. This magnetic cooler will enable cryogenic detectors for sensing infrared, x-ray, gamma-ray, and submillimeter radiation in future science satellites, as well as the detector systems in the Constellation-X (Con-X) and the Single Aperture Far-Infrared observatory (SAFIR). Scientific ap p - lica tions for this innovation include cooling for x-ray micro calorimeter spectrometers used for microanalysis, cryogenic particle detectors, and superconducting tunnel junction de tectors for biomolecule mass spectrometry. The cooler can be scaled to provide very large cooling capacities at very low temperatures, ideal for liquid helium and liquid hydrogen productions.

Chen, Weibo↗

NASA NTRS1975

Preliminary Study of Advanced Turboprops for Low Energy Consumption

The fuel savings potential of advanced turboprops (operational about 1985) was calculated and compared with that of an advanced turbofan for use in an advanced subsonic transport. At the design point, altitude 10.67 km and Mach 0.80, turbine-inlet temperature was fixed at 1590 K while overall pressure ratio was varied from 25 to 50. The regenerative turboprop had a pressure ratio of only 10 and an 85 percent effective rotary heat exchanger. Variable camber propellers were used with an efficiency of 85 percent. The study indicated a fuel savings of 33 percent, a takeoff gross weight reduction of 15 percent, and a direct operating cost reduction of 18 percent was possible when turboprops were used instead of the reference turbofan at a range of 10 200 km. These reductions were 28, 11, and 14 percent, respectively, at a range of 5500 km. Increasing overall pressure ratio from 25 to 50 saved little fuel and slightly increased takeoff gross weight.

Kraft, G. A.↗

NASA NTRS1987

Mars manned transportation vehicle

A viable power system technology for a surface transportation vehicle to explore the planet Mars is presented. A number of power traction systems were investigated, and it was found that a regenerative hydrogen-oxygen fuel cell appears to be attractive for a manned Mars rover application. Mission requirements were obtained from the Manned Mars Mission Working Group. Power systems weights, power, and reactants requirements were determined as a function of vehicle weights for vehicles weighing from 6,000 to 16,000 lb (2,722 to 7,257 kg), (Earth weight). The vehicle performance requirements were: velocity, 10 km/hr; range, 100 km; slope climbing capability, 30 deg uphill for 50 km; mission duration, 5 days; and crew, 5. Power requirements for the operation of scientific equipment and support system capabilities were also specified and included in this study. The concept developed here would also be applicable to a Lunar based vehicle for Lunar exploration. The reduced gravity on the Lunar surface, (over that on the Martian surface), would result in an increased range or capability over that of the Mars vehicle since many of the power and energy requirements for the vehicle are gravity dependent.

Perez-Davis, Marla E.↗

NASA NTRS1989

Mars manned transportation vehicle

A viable power system technology for a surface transportation vehicle to explore the planet Mars is presented. A number of power traction systems were investigated, and it was found that a regenerative hydrogen-oxygen fuel cell appears to be attractive for a manned Mars rover application. Mission requirements were obtained from the Manned Mars Mission Working Group. Power systems weights, power, and reactants requirements were determined as a function of vehicle weights for vehicles weighting from 6,000 to 16,000 lb (2,722 to 7,257 kg), (Earth weight). The vehicle performance requirements were: velocity, 10 km/hr; range, 100 km; slope climbing capability, 30 deg uphill for 50 km; mission duration, 5 days; and crew, 5. Power requirements for the operation of scientific equipment and support system capabilities were also specified and included in this study. The concept developed here would also be applicable to a Lunar based vehicle for Lunar exploration. The reduced gravity on the Lunar surface, (over that on the Martian surface), would result in an increased range or capability over that of the Mars vehicle since many of the power and energy requirements for the vehicle are gravity dependent.

Perez-Davis, Marla E.↗

NASA NTRS2008

Novel Species of Non-Spore-Forming Bacteria

While cataloging cultivatable microbes from the airborne biological diversity of the atmosphere of the Regenerative Enclosed life-support Module Simulator (REMS) system at Marshall Space Flight Center, two strains that belong to one novel bacterial species were isolated. Based on 16S rRNA gene sequencing and the unique morphology and the taxonomic characteristics of these strains, it is shown that they belong to the family Intrasporangiaceae, related to the genus Tetrasphaera, with phylogenetic distances from any validly described species of the genus Tetrasphaera ranging from 96.71 to 97.76 percent. The fatty acid profile supported the affiliation of these novel strains to the genus Tetrasphaera except for the presence of higher concentrations of octadecenoic acid (C18:0) and cis-9-octadecenoic acid (C18:1), which discriminates these strains from other valid species. In addition, DNA-DNA hybridization studies indicate that these strains belong to a novel species that could be readily distinguished from its nearest neighbor, Tetrasphaera japonica AMC 5116T, with less than 20 percent DNA relatedness. Physiological and biochemical tests show few phenotypic dissimilarities, but genotypic analysis allowed the differentiation of these gelatin-liquefying strains from previously reported strains. The name Tetrasphaera remsis sp. Nov. is proposed with the type strain 3-M5-R-4(sup T) (=ATCC BAA-1496(sup T)=CIP 109413(sup T). The cells are Gram-positive, nonmotile, cocci, in tetrad arrangement and clusters. Spore formation is not observed. No species of Tetrashpaera has ever been isolated from airborne samples. Previous discoveries have come from soil and activated sludge samples. As other species of this genus have demonstrated enhanced biological phosphorus removal activity, further tests are required to determine if this newly discovered species would have bioremediation applications.

Briegel, Ariane↗

NASA NTRS1992

Regenerative life support technology challenges for the Space Exploration Initiative

Regenerative life support systems have been identified as one of the critical enabling technologies for future human exploration of space. This discipline encompasses processes and subsystems which regenerate the air, water, solid waste, and food streams typical of human habitation so as to minimize the mass and volume of stored consumables which must accompany the humans on a mission. A number of key technology challenges within this broad discipline are described, ranging from the development of new physical, chemical, and biological processes for regenerating the air, water, solid waste, and food streams to the development of improved techniques for monitoring and controlling microbial and trace constituent contamination. A continuing challenge overarching the development of these new technologies is the need to minimize the mass, volume, and electrical power consumption of the flight hardware. More important for long duration exploration missions, however, is the development of highly reliable, long-lived, self- sufficient systems which absolutely minimize the logistics resupply and operational maintenance requirements of the life support system and which ensure human safety through their robust, reliable operating characteristics.

Bilardo, Vincent J., Jr.↗

NASA NTRS2010

Testing a Regenerative Carbon Dioxide and Moisture Removal Technology

The National Aeronautics and Space Administration supported the development of a new vacuum-desorbed regenerative carbon dioxide and humidity control technology for use in short duration human spacecraft. The technology was baselined for use in the Orion Crew Exploration Vehicle s Environmental Control and Life Support System (ECLSS). Termed the Carbon Dioxide And Moisture Removal Amine Swing-bed (CAMRAS), the unit was developed by Hamilton Sundstrand and has undergone extensive testing at Johnson Space Center. The tests were performed to evaluate performance characteristics under range of operating conditions and human loads expected in future spacecraft applications, as part of maturation to increase its readiness for flight. Early tests, conducted at nominal atmospheric pressure, used human metabolic simulators to generate loads, with later tests making us of human test subjects. During these tests many different test cases were performed, involving from 1 to 6 test subjects, with different activity profiles (sleep, nominal and exercise). These tests were conducted within the airlock portion of a human rated test chamber sized to simulate the Orion cabin free air volume. More recently, a test was completed that integrated the CAMRAS with a simulated suit loop using prototype umbilicals and was conducted at reduced atmospheric pressure and elevated oxygen levels. This paper will describe the facilities and procedures used to conduct these and future tests, and provide a summary of findings.

Barta, Daniel J.↗