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At least 1,171 records · Page 65

High-Throughput Electrochemical Characterization of Aqueous Organic Redox Flow Battery Active Material

The development of redox-active organics for flow batteries providing long discharge duration energy storage requires an accurate understanding of molecular lifetimes. Herein we report the development of a high-throughput setup for the cycling of redox flow batteries. Using common negolyte redox-active aqueous organics, we benchmark capacity fade rates and compare variations in measured cycling behavior of nominally identical volumetrically unbalanced compositionally symmetric cells. We propose figures of merit for consideration when cycling sets of identical cells, and compare three common electrochemical cycling protocols typically used in battery cycling: constant current, constant current followed by constant voltage, and constant voltage. Redox-active organics exhibiting either high or low capacity fade rates are employed in the cell cycling protocol comparison, with results analyzed from over 50 flow cells.

Electrochemistry↗

Fast-neutron Multiplicity Counter for Passive and Active Measurements of Special Nuclear Material

We developed a fast-neutron multiplicity counter (FNMC) based on organic scintillators (liquid and stilbene). The system is able to detect correlated photon and neutron multiplets emitted by fission reactions. We tested the system both in passive and active operation mode, and present the results of the experiments, both carried out at the Zero Power Physics Reactor of Idaho National Laboratory. The system was operated in coincidence mode (with a gate time of 50 nanoseconds) and two calibration-based approaches were used to estimate the 240Pu effective (240Pueff) and 235U mass of the samples. In passive mode, we assayed two types of plutonium metal plates, i.e. PAHN and PANN, with a 240Pueff mass of 4.7 g and 25.05 g per plate, respectively. The 239Pu mass percentage was 74% for the PAHN and 95% for the PANN series. We measured neutrons emitted in coincidence by several plate assemblies, having an overall 240Pueff mass in the 4.7 g to 500 g range. In active mode, we characterized several uranium samples. We used two AmLi sources (~50000 neutrons emitted per second) to induce fission in the samples. The first six measured samples were certified reference materials (CRM, set 149), having a constant enrichment, i.e. 93.2 wt%, and mass in the range between 0.5 and 4 kg. Additionally, we assayed three CRM-146 samples, with constant total mass of 500 g and an enrichment of 20.1 wt%, 52.8 wt% and 93.2 wt%. In both configurations, the system succeeded in estimating the fissile mass of an unknown sample with a statistical uncertainty lower than 1% (4-minute assay) and 7% (10-minute assay), in passive and active mode, respectively. In passive mode, the statistical uncertainty is lower than the one achieved by standard 3He counters for plutonium metal samples of similar mass. The difference between the estimated and the declared 240Pueff mass, i.e., the bias error, measured by the fast neutron multiplicity counter was consistently lower compared to the bias error of a standard thermal system.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Carbon-carbon piston development

A new piston concept, made of carbon-carbon refractory-composite material, has been developed that overcomes a number of the shortcomings of aluminum pistons. Carbon-carbon material, developed in the early 1960's, is lighter in weight than aluminum, has higher strength and stiffness than aluminum and maintains these properties at temperatures over 2500 F. In addition, carbon-carbon material has a low coefficient of thermal expansion and excellent resistance to thermal shock. An effort, called the Advanced Carbon-Carbon Piston Program was started in 1986 to develop and test carbon-carbon pistons for use in spark ignition engines. The carbon-carbon pistons were designed to be replacements for existing aluminum pistons, using standard piston pin assemblies and using standard rings. Carbon-carbon pistons can potentially enable engines to be more reliable, more efficient and have greater power output. By utilizing the unique characteristics of carbon-carbon material a piston can: (1) have greater resistance to structural damage caused by overheating, lean air-fuel mixture conditions and detonation; (2) be designed to be lighter than an aluminum piston thus, reducing the reciprocating mass of an engine, and (3) be operated in a higher combustion temperature environment without failure.

Gorton, Mark P.↗

Thermally-Induced morphological evolution of spherical silica nanoparticles using in-operando X-ray scattering measurements

The assembly and morphology of pores determine thermodynamic, flow and reactive properties of confined fluids. Yet, there is a limited understanding of how pore architectures dynamically develop in engineered and natural materials. To develop a calibrated understanding of fluid properties in confinement, the synthesis of architected materials has been proposed. The design of geo-architected materials has to be informed by the dynamic evolution of the morphology in response to thermal or chemical events. Here, we probe thermally induced morphological evolution of spherical silica nanoparticles 220 ± 30 nm in diameter using in-operando Ultra-Small and Small Angle X-Ray Scattering measurements. The calcination experiments demonstrated that at temperatures up to 600 °C the pore radii remained in the range of 2.15 nm–2.35 nm and the particle diameters in the range of 220 ± 30 nm. Sintering these calcined silica nanoparticles to temperatures up to 1050 °C reduced the pore size from 2.2 ± 0.1 nm to ~1.8–0.2 nm. These changes corresponded to the formation of siloxane (Si-O-Si) bridges resulting from dehydroxylation. The characteristic pore radius of sintered particles was also confirmed by N 2 adsorption measurements. These studies represent the use of non-invasive dynamic characterization methods such as X-ray scattering to elucidate thermally induced morphological evolution in architected siliceous materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Application of NSUF Capabilities Towards Understanding the Emulation of High Dose Neutron Irradiations with Ion Beams

Development of new materials for current nuclear power plants (NPPs) or materials for new NPPs requires extensive research, development, and deployment programs. Central to these efforts, particularly for core internals, are studies on the microstructural and mechanical changes due to neutron irradiation. These radiation effects studies are typically completed using materials test reactors followed by expensive and time-consuming post-irradiation examinations (PIE). This sluggish approach has severely limited the nuclear materials field to develop new materials or verify materials for new reactor design use. It is also very difficult to achieve the high levels of damage proposed for future reactors. A logical approach to accelerating the field is the application of ion beams to simulate neutron damage, especially for high dose applications. Ion beams have been used for decades to study radiation effects but not to emulate high dose reactor irradiations. In this regard, new (or renewed) methods for ion beam irradiations, new developments in materials characterization, and greater understanding on the governing mechanisms controlling observed radiation effects have led to a need for further studies to refine the technique. A primary challenge is the ability to determine the ion irradiation conditions that produce microstructures and mechanical properties relevant to in-core neutron irradiation conditions. A large, multi-disciplinary, multi-laboratory program deemed the High Fidelity Ion Beam Simulation of High Dose Neutron Irradiation has been formed to assess and overcome the challenges associated with emulating high dose neutron irradiations using ion beams. Central to this program is the use of dual-beam ion irradiations and corresponding neutron irradiations within the BOR-60 fast reactor. These irradiations have produced hundreds of specimens for microstructural and mechanical characterization. A significant issue regarding the samples is the radioactivity of the neutron irradiated specimens as well as the need to characterize both irradiation types using the same equipment to maintain consistency and repeatability. The use of the Nuclear Science User Facilities (NSUF) has been central towards overcoming the mentioned issues and thereby enabling robust PIE in both the ion and neutron irradiated specimens of interest. In particular, the electron microscopes housed within the Low Activation Materials Development and Analysis (LAMDA) facility at Oak Ridge National Laboratory (ORNL) - an NSUF partner facility - has been instrumental in gathering high quality data for analysis. This paper will briefly highlight the PIE efforts using the NSUF capabilities within LAMDA.

36 MATERIALS SCIENCE↗

Fostering a Guiding Multiscale Model for the Development of Advanced MgB 2 Hydrogen Storage Materials (Final Technical Report)

Project Goal and Objective. The demand for energy and for an upgraded energy infrastructure has steadily grown, as have the needs for energy independence and alternatives to our reliance on petroleum. Hydrogen is considered the most viable fuels for wide-scale implementation in the near future as it is less-polluting, non-toxic, and has more stored energy than petroleum. It is envisioned that hydrogen can eventually become the prime energy carrier, integrating the transportation, grid, and chemical sectors in a way that improves resiliency, diversifies feedstocks, and affords new economic opportunities. A key remaining challenge is the development materials with enhanced gravimetric and volumetric hydrogen storage capacities that offer a higher performance than compressed gas. These materials would eliminate the need for large-scale compression, thereby dramatically reducing the footprint and cost of gas storage. The high gravimetric and volumetric hydrogen capacities of complex hydrides has prompted an intensive investigation of the potential of this class of materials as hydrogen storage media over the past 25 years. Among the many complex hydrides that have been explored, magnesium borohydride, Mg(BH 4 ) 2 , has been found to possess the best combination of practical thermodynamic properties. These include a gravimetric H 2 density of 14.9 wt% H 2 and thermodynamics for the dehydrogenation of Mg(BH 4 ) 2 to MgB 2 (equation 1) (ΔH° = 39 kJ/mol H 2 , ΔS = 112 J/K mol H 2 ) which lie in the narrow window required Mg(BH 4 ) 2 $\Leftrightarrow$ MgB 2 + 4 H 2 (1) for reversibility under moderate pressure and temperature. However, overcoming the extremely slow kinetics of the reversible release of hydrogen by this material in the solid state is a daunting challenge. At temperatures greater than 400 °C, the borohydride releases up to 14 wt% hydrogen giving MgB 2 . We discovered that the direct re-hydrogenation of MgB 2 to Mg(BH 4 ) 2 can be accomplished under 950 bar H 2 at 400 °C. While this demonstrated that complete reversibility can be achieved, the conditions employed are far too extreme for commercial hydrogen storage applications. More recently, we found through US DOE funded research projects (EERE HyMARC and HySCOR), that hydrogen cycling, can be accomplish at much milder conditions upon modification of the borohydride or boride. Guided by these discoveries these discoveries, the objective of this research project was to obtain key information that will enable the development of a model of reversible hydrogenation of MgB 2 to Mg(BH 4 ) 2 . The ultimate goal of our efforts is to attain a model of this transformation that can be utilized to accelerate development further advanced materials. This project directly follows on discoveries that were made over the course of a US DOE, EERE HyMARC project that was focused on improvement of the hydrogen cycling kinetics of modified MgB 2 . We found that that mechanical milling with graphene results the desired, pronounced kinetic enhancement. The dramatic lowering of the conditions required for the hydrogenation of MgB 2 is a significant step towards overcoming its chemical inertness allowing its development as a practical onboard hydrogen storage material. However, the exact nature of the modification(s) of MgB 2 that is responsible for its activation towards hydrogenation is completely unknown. This situation is not unique, as efforts to develop hydrogen storage materials typically have a narrow focus rather than a comprehensive approach that takes atomic level bonding and structure; molecular dynamics; long range, nano- and mesoscale-structure and their interconnection all into account. The goal of this project was the development of a comprehensive, multi-scale computational model of reversible hydrogenation of MgB 2 to Mg(BH 4 ) 2 that can be utilized for development of higher performance versions of the modified material. Development of the model requires determination of: 1) the bulk, nano-scale, and meso-scale structural changes occurring at elevated pressure following mechano-chemical modification of MgB 2 ; 2) the reaction pathway of the reversible hydrogenation of MgB 2 to Mg(BH 4 ) 2 ; 3) the effect of elevated pressure and mechano-chemical modification on the chemical reaction pathways; 4) the interactions at solid-gas interfaces; and particle surfaces; and 5) the kinetics and thermodynamic parameters associated with each step of the hydrogenation reaction pathway. This investigation required advanced techniques as preliminary, standard XRD, 11 B NMR, and FTIR analysis showed no signs of material modification. In order to gain this level of understanding of modified MgB 2 , required the teaming of a diverse group of experts and state-of-the art experimental capabilities at the University of Hawaii at Manoa (UHM) and collaborating National Laboratories: Craig Jensen , Department of Chemistry (PI and Project Director), solid state, solution, and high pressure NMR spectroscopy; solid-state synthesis; and high pressure hydrogenation (collaboration with SNL); Godwin Severa , Hawaii Natural Energy Institute (co-PI) calorimetry; infrared and Raman spectroscopy (collaboration with NREL); Dera , high pressure X-ray diffraction including in situ experiments (collaboration with ANL); Hope Ishii , Hawaii Institute of Geophysics electron microscopy investigations (collaboration with LBNL); and Joe Brown , Mechanical Engineering , material electronic structure and electric field effects.

08 HYDROGEN↗

Report of the Panel on Propulsion

Propulsion, while conventionally included on the list of important aeronautical disciplines along with aerodynamics, structures, etc., is in itself a systems endeavor, analogous to the engineering of the entire vehicle; indeed propulsion encompasses important aspects of all the other disciplines. In recognition of this fact, the panel focused its discussion on those aspects of the key disciplines that are especially or uniquely important to propulsion. From the initial development of the airplane, the propulsion system has been recognized as one of the pacing technologies. It is perhaps because of the technological disparity between the reciprocating engine and the primitive airframe that the two remained relatively and separate, were developed somewhat independently, usually by different organizations. In recent years, the maturing of the gas turbine power plant and the advance in high-speed airframes have rendered this separation somewhat artificial. The power plant and the airframe now share common structural and aerodynamic elements; as the flight Mach number rises, the degree of interaction increases. By the year 2000, this interdependence will have increased in many respects to a point where independent design may not be practical or possible. During the period since the initiation of the aircraft gas turbine, the solid propellant rocket and the liquid propellant rocket, a vast array of other novel engines have been studied, covering the full spectrum of flight conditions from low subsonic to hypersonic and transatmospheric flight. In each instance, performance limits have been investigated under the assumption that current technology or reasonably foreseeable technology would be available for their development. Among the extensive list of advanced, high-performance concepts and cycles examined are the hypersonic ramjet, the variable cycle, runway-to-orbit airbreathing engine, the ram rocket (airbreathing and rich solid propellant rocket), and the air turborocket. At various times, these systems have come relatively close to meriting development and application. In many instances, limitations of materials and technologies curtailed development. As important and with almost equal frequency, the lack of commercial or military utility of the concept precluded the necessary funding. It is instructive to note that two former items on this list, the turbofan (bypass engine) and the high-speed turboprop, are respectively a mainstay engine and a promising development. In the case of the turbofan, its full potential could not be realized until turbine cooling technology had been developed and new materials developed to permit the construction of transonic fans. In the case of the highspeed turbopropeller engine, not only were the material and turbine technologies needed, but, in addition, the rise in fuel costs provided the impetus to take advantage of its favorable fuel consumption characteristic. As the basic technologies progress and as new missions become attractive, the engines in the foregoing list become candidates for new feasibility studies and further technology development. At the present time, the ram rocket is the prime contender to augment the range of small missiles. Of interest also is the hypersonic ram jet and its logical extension, the runway-to-orbit airbreathing engine. Much of this report deals with the development of current or near-future power plant concepts. First, the motivating factors for aeronautical propulsion research are reviewed as a reminder of the importance of continued effort in a field that has often been characterized as mature. Next, technical areas are discussed in which the panel feels additional research effort is warranted and would lead to the realization of the technological potentials between now and the year 2000. Under these guidelines, new cycles (e.g., isothermal energy exchange) were not considered by the panel. Finally, although facility requirements were not a prime consideration in the current projections, the panel believes that the increasing complexity of propulsion systems; the need for more refined interaction between propulsion system, airframe, and controls; and increasing operation in adverse weather will require test capabilities beyond those now available (see appendix). Enhanced test capability is needed in the areas of propulsion airframe integration and in largescale icing research with proper concurrent treatment of altitude, temperature, and speed.

Kerrebrock, Jack L.↗

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗

Sliding electrical contact materials

The results of research programs to develop sliding electrical contact materials, both brushes and slip rings, are discussed. Problems attendant to operating sliding contacts in a vacuum are defined; limitations of commercial materials in solving these problems are described, and special materials and surface finish conditions which have resulted in solutions to these problems are presented. Data from operational tests on the newly developed materials are compared with similar data obtained from materials now used as standards in consumer products. Possible commercial applications of the more efficient sliding contact materials are discussed briefly.

Sliding contact↗

High temperature be panel development

Beryllium materials have been used for many aerospace applications over the years. Most of these applications have been fairly ambient environments. The possibility of fabricating beryllium panels for high temperature applications up to 1200 F is investigated. Joining alloys were reviewed, tested and evaluated for high temperature applications.

Hardesty, R.↗

Predicting Pressure Drop In Porous Materials

Theory developed to predict drop in pressure based on drag of individual fibers. Simple correlation method for data also developed. Helps in predicting flow characteristics of many strain-isolation pad (SIP) glow geometries in Shuttle Orbiter tile system. Also helps in predicting venting characteristics of tile assemblies during ascent and leakage of hot gas under tiles during descent. Useful in study of mechanics of flows through fibrous and porous media, and procedures applicable to purged fiberglass insulation, dialysis filters, and other fibrous and porous media.

Lawing, Pierce L.↗

Radiation Transmission Properties of In-Situ Materials

The development of a permanent human presence in space is a key element of NASA's strategic plan for the Human Exploration and Development of Space (HEDS). The habitation of the International Space Station (ISS) is one near-term HEDS objective; the exploration and settlement of the moon and Mars are long-term goals of that plan. Achieving these goals requires maintaining the health and safety of personnel involved in such space operations at a high level, while at the same time reducing the cost of those operations to a reasonable level. Among the limiting factors to prolonged human space operations are the health risks from exposure to the space ionizing radiation environment. In order to keep the risk of radiation induced cancer at acceptable levels, it is necessary to provide adequate shielding from the ionizing radiation environment. The research presented here is theoretical and ground-based experimental study of the neutron production from interactions of GCR-like particles in various shielding components. An emphasis is placed here on research that will aid in the development of in-situ resource utilization. The primary goal of the program is to develop an accurate neutron-production model that is relevant to the NASA HEDS program of designing technologies that will be used in the development of effective shielding countermeasures. A secondary goal of the program is the development of an experimental data base of neutron production cross sections and thick-target yields which will aid model development.

Heilbronn, L.↗

Switchable Shape Memory Alloys (SMA) Thermal Materials Project

Develop 2-way switchable thermal systems for use in systems that function in cold to hot temperature ranges using different alloy designs for SMA system concepts. In this project, KSC will specifically address designs of two proof of concept SMA systems with transition temperatures in the 65-95 C range and investigate cycle fatigue and "memory loss" due to thermal cycling.

thermal↗

Hexavalent Chromium IV-Free Primer Development

Primer materials provide corrosion protection for metal parts as well as an increased adhesion between metallic substrates and thermal protection systems (TPSs). Current primers for use in cryogenic applications contain hexavalent chromium. This hexavalent chromium provides excellent corrosion protection even in a cryogenic environment, but it is a carcinogen that requires special equipment and waste control procedures to use. The hazardous nature of hexavalent chromium makes it an obsolescence risk in the future. This study included two phases of evaluation. Thirteen primers were initially identified as candidates and twelve of those primers were tested in phase 1. Four of the best performing candidates from phase 1 continued into phase 2 testing. Phase 1 testing consisted mostly of liquid constituent and physical property testing. Cryoflex and salt fog testing were included in phase 1 because of their importance to the overall success of a candidate material. Phase 2 consisted of physical, thermal, and mechanical properties for nominally processed and fabricated specimens.

Alldredge, Michael J.↗

Measuring Thermal Conductivity and Moisture Absorption of Cryo-Insulation Materials

NASA is seeking to develop thermal insulation material systems suitable for withstanding both extremely high temperatures encountered during atmospheric re-entry heating and aero- braking maneuvers, as well as extremely low temperatures existing in liquid fuel storage tanks. Currently, materials used for the high temperature insulation or Thermal Protection System (TPS) are different from the low temperature, or cryogenic insulation. Dual purpose materials are necessary to the development of reusable launch vehicles (RLV). The present Space Shuttle (or Space Transportation System, STS) employs TPS materials on the orbiter and cryo-insulation materials on the large fuel tank slung under the orbiter. The expensive fuel tank is jettisoned just before orbit is achieved and it burns up while re-entering over the Indian Ocean. A truly completely reusable launch vehicle must store aR cryogenic fuel internally. The fuel tanks will be located close to the outer surface. In fact the outer skin of the craft will probably also serve as the fuel tank enclosure, as in jet airliners. During a normal launch the combined TPS/cryo-insulation system will serve only as a low temperature insulator, since aerodynamic heating is relatively minimal during ascent to orbit. During re-entry, the combined TPS/cryo-insulation system will serve only as a high temperature insulator, since all the cryogenic fuel will have been expended in orbit. However, in the event of an.aborted launch or a forced/emergency early re-entry, the tanks will still contain fuel, and the TPS/cryo-insulation will have to serve as both low and high temperature insulation. Also, on long duration missions, such as to Mars, very effective cryo-insulation materials are needed to reduce bod off of liquid propellants, thereby reducing necessary tankage volume, weight, and cost. The conventional approach to obtaining both low and high temperature insulation, such as is employed for the X-33 and X-34 spacecraft, is to use separate TPS and cryo-insulation materials, which are connected by means of adhesives or stand-offs (spacers). Three concepts are being considered: (1) the TPS is bonded directly to the cryo-insulation which, in turn, is bonded to the exterior of the tank, (2) stand-offs are used to make a gap between the TPS and the cryo-insulation, which is bonded externally to the tank, (3) TPS is applied directly or with stand-offs to the exterior so the tank, and cryo-insulation is applied directly to the interior of the tank. Many potential problems are inherent in these approaches. For example, mismatch between coefficients of thermal expansion of the TPS and cryo-insulation, as well as aerodynamic loads, could lead to failure of the bond. Internal cryo-insulation must be prevent from entering the sump of the fuel turbo-pump. The mechanical integrity of the stand-off structure (if used) must withstand multiple missions. During ground hold (i.e., prior to launch) moisture condensation must be minimized in the gap between the cryo-insulation and the TPS. The longer term solution requires the development of a single material to act as cryo- insulation during ground hold and as TPS during re-entry. Such a material minimizes complexity and weight while improving reliability and reducing cost.

Lambert, Michael A.↗