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NASA Aerospace Flight Battery Systems Program

The major objective of the NASA Aerospace Flight Battery Systems Program is to provide NASA with the policy and posture to increase and ensure the safety, performance and reliability of batteries for space power systems. The program plan has been modified in the past year to reflect changes in the agency's approach to battery related problems that are affecting flight programs. Primary attention in the Battery Program is being devoted to the development of an advanced nickel-cadmium cell design and the qualification of vendors to produce cells for flight programs. As part of a unified Battery Program, the development of a nickel-hydrogen standard and primary cell issues are also being pursued to provide high-performance NASA Standards and space qualified state-of-the-art primary cells. The resolution of issues is being addressed with the full participation of the aerospace battery community.

Manzo, Michelle A.

Gateway Element and Payload Materials Outgassing Analyses: HALO, HERMES, and ERSA

Gateway was intended to be humanity’s first space station around the Moon, but its development has been paused as the National Aeronautics and Space Administration (NASA) shifts focus to achieving the United States’ National Space Policy goals. Instead of an orbiting lunar outpost, NASA will now pursue the development of a lunar surface base to support a sustained human presence on the Moon. Before the program’s pause, Gateway’s Induced Environments team worked to ensure payloads and elements (i.e., modules) complied with induced environment requirements. Methods developed and insights gained from this work will have applicability to NASA’s Moon Base and the potential repurposing of Gateway elements and payloads, as well as to induced environments modeling for future space stations. The Gateway program’s induced environment included molecular contamination, electric thruster plume sputter and redeposition, and lunar dust transfer from the Human Landing System (HLS). Primary sources of external molecular contamination included materials outgassing, chemical thruster plume contamination, and vacuum venting. The focus of this paper will be on element- and payload-level materials outgassing analyses performed for Gateway Configuration 1, extending the previously-developed framework for Gateway system-level external molecular contamination modeling. Gateway Configuration 1 consisted of the Power and Propulsion Element (PPE) and the Habitation and Logistics Outpost (HALO). It also included payloads like the European Radiation Sensor Array (ERSA) attached to PPE and the Heliophysics Environmental and Radiation Measurement Experiment Suite (HERMES) attached to HALO. The element- and payload-level analyses to be introduced in this paper for HALO, HERMES, and ERSA enabled high-fidelity descriptions of Gateway’s external molecular contamination environment. Approaches to geometric modeling, meshing, outgassing rate assignment, molecular transport modeling, and analysis methodology will be presented. Element and payload contaminant deposition onto sensitive Gateway receiver surfaces will be summarized and results compared to induced environment requirements. While these results incorporate refinements made over the course of the program, they were not intended to be final. Therefore, modeling assumptions and inputs, potential improvements, and lessons-learned will be documented to inform future work on Moon Base, repurposed elements and payloads, and other space stations.

Gateway

First-Principles Investigation of Phase Transitions in RuNb, RuTa, and Ru-Nb-Ta Ultrahigh Temperature Shape Memory Alloys

Ultrahigh temperature shape memory alloys (UHT-SMAs) have transition temperatures above 600 C, and they have found applications for sensing and actuating devices in aerospace industry. Among very few such UHT-SMAs currently known are Ru-based alloys such as RuNb and RuTa, whose martensite structures and phase transitions are totally different from those of NiTi-based SMAs and were poorly understood. In this work, we carried out a systematical study of RuNb using first-principles total energy calculations and molecular dynamics (MD) simulations. The transition paths and mechanisms in cubic → tetragonal →monoclinic transitions are revealed. and the transition sequence and martensitic transition temperatures are determined (MTTs) by evaluating the Gibbs free energies using thermodynamic integration. The calculated MTTs are in very good agreement with the experimental data. We found that the monoclinic phase at the second transition has the 𝑃21/m symmetry instead of experimentally identified 𝑃2/m. Our calculations demonstrate that RuTa has very similar phase transitions to those of RuTa. Furthermore, we studied the Ru0.5Nb0.25Ta0.25 ternary. Our results can explain the measured significant drop of MTT (~ 200 C) in the second transition for Ru0.5Nb0.25Ta0.25 compared with those of RuNb and RuTa, while in the first transition its MTT is between MTTs of RuNb and RuTa. The insights gained by this study and the verified ab initio methods for accurate MTT calculations can be applied to fast screen and quantitatively design novel UHT-SMAs having similar properties with desirable MTTs and much reduced cost.

Zhigang Wu

From Peenemuende to Outer Space

Commemorating the Fiftieth Birthday of Wernher von Braun. Launch vehicles and spacecraft for exploration of space and planets

SPACECRAFT

Engineering and Abuse Testing of Panasonic Lithium-Ion Battery and Cells

This viewgraph presentation reviews the performance testing of Lithium Ion batteries and cells under different conditions of charge and discharge. The tests show that the 0.5 C rate of charge and discharge might be the ideal condition for long term cycling. It reviews the issues of overcharge and overdischarge of the cells. The cells and the battery have adequate protection under both conditions to prevent any catastrophic occurrences. Temperatures above 150 C are required to vent the cells or cause a thermal runaway, Since this situation is non-credible in the cabin of the Space Shuffle or ISS this should not pose a problem. The presentation includes graphs and charts showing the charge and discharge capacities of the battery and also the current and voltage profiles. A view of a circuit board which contains the controlling mechanism for the battery is also shown.

Jeevarajan, Judith A.

Riddles About the Origin and Thermal History of the Moon

Analyses of lunar rocks have confirmed that the interior of the Moon has been subjected to magmatic differentiation, as has been determined by calculation of the thermal history of the Moon. However, it appears that differentiation occurred so early that it could not have been related to heating by long-lived radioactive elements, but rather indicates a high initial temperature of the Moon. The reasons for the high initial temperature remain unknown. The presence of a central, partially melted area revealed by seismic observations forces us to reject convective models of the Moon, while the dimensions of this area, together with the measured heat fluxes from the interior, serve as "boundary conditions" for any new calculations of the thermal history for a two-layered differentiated model of the Moon operative over the past 3.5 billion years. If we start with the early differentiation of the Moon and the high content of long-lived radioactive elements in it, explanation of its current thermal properties represents no difficulty. But these prerequisites themselves remain unexplained. Due to the continuing controversy concerning the true nature of the process of magmatic differentiation of the Moon, estimation of the composition of the entire Moon on the basis of analyses of surface rock remains unreliable, and use of these estimates to clarify the origin of the Moon is premature. Existing hypotheses concerning the origin of the Moon encounter dynamic difficulties, as well as difficulties with explanation of the high initial temperature, to say nothing of the difficulty involved in explaining the proposed differences in the composition of the Earth and Moon.

B Yu Levin

Ice in Convective Storm Environments: Assessing Impacts of Microphysics on Simulated Reflectivities

Satellite radar retrievals of clouds and precipitation rely on assumptions about the microphysical properties of hydrometeors such as particle size distributions (PSDs) and massdimensional relationships, which have been shown to vary in distinct environments. A deeper understanding of linkages between mass-dimensional relationships, ice crystal shape, and radar reflectivities across cloud and precipitation regimes is necessary for developing new retrievals for upcoming satellite radar missions, including the INvestigation of Convective UpdraftS (INCUS), as well as future missions that will feature space-borne radars observing clouds, convection, and precipitation. This study investigates ice microphysical characteristics through aircraft in-situ and remote sensing observations from two convective events during the Mid-latitude Continental Convective Clouds Experiment (MC3E) in the Southern Great Plains, and tests implications for ice particle habit in forward modeled radar observations. During MC3E, the Ka/Ku- band High Altitude Imaging Wind and Rain Airborne Profiler (HIWRAP) was onboard the NASA ER-2 aircraft, while in-situ measurements were taken onboard the University of North Dakota Citation. In-situ PSDs and particle shape information from optical array probe data are used to forward model radar reflectivities from particle scattering databases and are compared against HIWRAP reflectivities. Various particle combinations can be used to find agreement with HIWRAP observations, and the forward modeled reflectivities were sensitive to particle type. Varying the riming on the aggregate and graupel particles resulted in larger than 10 dB differences in reflectivities. The in-situ and radar observations imply the occurrence of aggregation, size sorting and lofting particles.

Julia A. Shates

The Canadian Galactic Emission Mapper: A New 8-10 GHz Telescope To Map the Polarization of the Northern Sky

The Canadian Galactic Emission Mapper (CGEM) radio telescope is mapping polarized Galactic foregrounds from 8-10 GHz to aid in the search for B-modes in the Cosmic Microwave Background (CMB). Here we describe the design and early on-sky characterization of the CGEM optics. CGEM employs an on-axis, hat feed optical design that is a body of revolution (BOR) and exhibits excellent intrinsic polarization purity. We describe how we have optimized the optics with a novel framework that can directly minimize simulated intensity to polarized intensity (T → P) leakage in angular power spectrum space. The optimized optics exhibit simulated T → P leakage that is orders of magnitude below anticipated CℓBB for r = 10 −3 when scaled from 8-10 GHz to the CMB observing window near 95 GHz. We go on to describe the mechanical design of the optics, including a novel secondary mirror support made from Astroquartz composite that has low loss, low dielectric constant, and preserves the BOR symmetry of the optics. We then showcase the early on-sky performance of the optics with observations of the Sun and satellites, which probe the beam to 40dB down from the peak. A beam model for the deployed CGEM optics based on electromagnetic simulations is in excellent agreement with the on-sky data.

cosmic microwave background

Impacts of Reduced Pressure Atmospheres on Environmental Control and Life Support Systems (ECLSS) Architectures

The study found that while nine subsystems are viable without modification at 10.2 psia, only three remain acceptable at 8.2 psia. Material flammability presents the most critical hurdle in the 8.2 psia/34-40% O 2 environment, where 70% of the assessed subsystems will require material replacements, many of which have yet to be developed. Ultimately, adapting ISS heritage hardware to these exploration conditions will introduce varied mass, power (e.g., increased fan speeds), and significant schedule impacts driven by the need for extensive testing, redesign, and recertification. The report concludes with specific recommendations for targeted analysis and testing to quantify these impacts and guide necessary design modifications.

Environmental Control and Life Support Systems

Integrated Flywheel Technology 1983

Topics of discussion included: technology assessment of the integrated flywheel systems, potential of system concepts, identification of critical areas needing development and, to scope and define an appropriate program for coordinated activity.

Claude R Keekler

Spacecraft battery reconditioning cost considerations

Cost considerations for spacecraft battery reconditioning are studied. Results indicate that the cost of performing reconditioning is minuscule compared with spacecraft system investment. Results also indicate that spacecraft life extension of a few days justifies incorporation of reconditioning circuitry.

Vanommering, G.

Skylab Experiment M552: Exothermic Brazing

The M552 Skylab experiment reveals that brazing in space is feasible. It successfully demonstrated the ability to retain molten metal within a braze tube joint system. Surface energy was the dominant operative force system controlling liquid metal for this experiment. The zero gravity environment for brazing resulted in several differences; increased solubility, increased liquid spreading, more uniform menisci (liquid/vapor interface) and a reduction of braze alloy shrinkage defects. The residual radioactive intensity and location of the redistributed isotope was interpreted to provide a sequential history of braze alloy movement during the melt-flow-solidification stages of the process. Convection theory applied to M552 was validated but some results were not explainable by it, i.e., increased nickel transport and the radial mixing of the silver isotope on samples SLN-2 and SLN-4. All characteristics of thermal analysis appeared to react as expected but heat conduction rates increased because of increased extent, rate and uniformity of braze alloy spreading.

J R Williams

Research Achievements Review, Volume II

Materials research - diffusion bonding methods, stress corrosion tests, nondestructive testing, material designs for electronic equipment, and nonmetallic material development.

Materials Science

The Benard Problem: A Comparison of Finite Difference and Spectral Collocation Eigen Value Solutions

The application of spectral methods, using a Chebyshev collocation scheme, to solve hydrodynamic stability problems is demonstrated on the Benard problem. Implementation of the Chebyshev collocation formulation is described. The performance of the spectral scheme is compared with that of a 2 nd order finite difference scheme. An exact solution to the Marangoni-Benard problem is used to evaluate the performance of both schemes. The error of the spectral scheme is at least seven orders of magnitude smaller than finite difference error for a grid resolution of N = 15 (number of points used). The performance of the spectral formulation far exceeded the performance of the finite difference formulation for this problem. The spectral scheme required only slightly more effort to set up than the 2 nd order finite difference scheme. This suggests that the spectral scheme may actually be faster to implement than higher order finite difference schemes.

J Raymond Lee Skarda

Manned Lunar Landing Via Rendezvous

In any mission description, the vehicles, the flight profiles, and the astrionics hardware to im- plement the mission are all tightly interwoven things. A final result evolves only after many iterations to the solution are made. This paper will describe one of these iterations in the Saturn C-5 Earth Orbit Rendezvous approach to the Manned Lunar Landing Program. Since the iter- ation to be described in an nthone, there exists some basis for the hope that the perturbation from the final solution is small. This paper is not concerned with the landing itself, but only with those operations leading to injection of the space craft into the lunar trans- fer trajectory. However, as is to be expected, it is the target conditions which set the pace for the overall operation. The entire operation must be sized to culminate at a time and place which places the lunar target in an attainable position. The procedure would call for a burst of activity lasting over a relatively short time as compared to the long and extensive preparations leading up to it. The activity must be aimed at the opening of the lunar "launch window". Figure 1 illustrates the variation in the velocity increment required to launch a vehicle into a lunar transfer trajectory from a 485 kilometer earth orbit. The minima are at irregularly spaced intervals and are a func- tion of the inclination of the lunar and the earth satellite planes and of the position of the moon in its orbit around the earth (i. e. , the day of the month). In an operations analysis these spacings will influence the number of vehicles on the launch pad (primary and back-up) , their state of readi- ness, the firing rate, and also the flight profile to be chosen. Whether it is decided to go by "con- necting" or by "tanking" mode, the objective must be to get the spacecraft in the launch ready state at the opening of one of these launch windows. It may be desired that the first vehicle be capable of remaining in a functionally capable state even after bridging one or more of the gaps between the windows. This consideration will influence the design of the vehicles as well as the operational modes to be designed into the flight control hard- ware. For example, a sleep switch may be de- sirable from the standpoint of savings in battery we ight.

LUNAR LANDING

Lightweight bipolar storage battery

An apparatus [10] is disclosed for a lightweight bipolar battery of the end-plate cell stack design. Current flow through a bipolar cell stack [12] is collected by a pair of copper end-plates [16a,16b] and transferred edgewise out of the battery by a pair of lightweight, low resistance copper terminals [28a,28b]. The copper terminals parallel the surface of a corresponding copper end-plate [16a,16b] to maximize battery throughput. The bipolar cell stack [12], copper end-plates [16a,16b] and copper terminals [28a,28b] are rigidly sandwiched between a pair of nonconductive rigid end-plates [20] having a lightweight fiber honeycomb core which eliminates distortion of individual plates within the bipolar cell stack due to internal pressures. Insulating foam [30] is injected into the fiber honeycomb core to reduce heat transfer into and out of the bipolar cell stack and to maintain uniform cell performance. A sealed battery enclosure [ 22] exposes a pair of terminal ends [26a,26b] for connection with an external circuit.

Rowlette, John J.