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Ceramics for Molten Materials Containment, Transfer and Handling on the Lunar Surface

As part of a project on Molten Materials Transfer and Handling on the Lunar Surface, molten materials containment samples of various ceramics were tested to determine their performance in contact with a melt of lunar regolith simulant. The test temperature was 1600 C with contact times ranging from 0 to 12 hours. Regolith simulant was pressed into cylinders with the approximate dimensions of 1.25 dia x 1.25cm height and then melted on ceramic substrates. The regolith-ceramic interface was examined after processing to determine the melt/ceramic interaction. It was found that the molten regolith wetted all oxide ceramics tested extremely well which resulted in chemical reaction between the materials in each case. Alumina substrates were identified which withstood contact at the operating temperature of a molten regolith electrolysis cell (1600 C) for eight hours with little interaction or deformation. This represents an improvement over alumina grades currently in use and will provide a lifetime adequate for electrolysis experiments lasting 24 hours or more. Two types of non-oxide ceramics were also tested. It was found that they interacted to a limited degree with the melt resulting in little corrosion. These ceramics, Sic and BN, were not wetted as well as the oxides by the melt, and so remain possible materials for molten regolith handling. Tests wing longer holding periods and larger volumes of regolith are necessary to determine the ultimate performance of the tested ceramics.

Standish, Evan↗

NASA JSC’s Simulant Development Lab Capabilities and Artemis Testing

The Simulant Development Lab (SDL) is a multifunctional collaborative workspace that supports the development, curation, analysis, testing, and distribution of planetary regolith simulants – including lunar, Martian, asteroidal, and other granular materials. The lab provides a multidisciplinary setting for scientific characterization of simulant physical properties and for engineering evaluations conducted with simulant test beds. To enable this work, the SDL curates and maintains a stock of more than 35 metric tons of simulant material. To evaluate these materials and support testing goals, the lab is equipped with a comprehensive suite of processing tools and analytical instruments. These capabilities enable the SDL’s mission at NASA’s Johnson Space Center to distribute, develop, process, characterize, and test regolith simulants for mission relevant applications. Through controlled and repeatable testing environments that replicate the physical and compositional properties of lunar regolith, the SDL supports Artemis hardware maturation, providing safe, Earth‑based analogs for evaluating systems that must withstand regolith dust interactions, physical wear and abrasion, and operational loads. The facility’s extensive simulant inventory and integrated geological and engineering test infrastructure accelerate technology readiness for Artemis and future exploration campaigns (e.g., future crewed or robotic missions to Mars).

Simulant Development Lab↗

Overview of Plume-Surface Interaction Data from Subscale Inert Gas Testing at NASA MSFC Test Stand 300 Vacuum Facilities

Maturation and validation of predictive modeling capabilities for plume-surface interaction, and the effects caused by the impingement of rocket engine exhaust on surface regolith, require relevant, highly characterized ground test data. The multi-phase nature of this problem poses challenges to ground testing across physical scaling, test environments and techniques, and diagnostics. NASA has developed a Physics Focused Ground Test (PFGT) of plume-surface interaction to address this need. The PFGT is a subscale, inert-gas experiment at Mars- and Lunar-relevant ambient pressure conditions that will provide critical data for model validation of cratering, ejecta, and plume physics. In this test, the ambient pressure in a vacuum chamber will be varied, along with the height of a supersonic nozzle above a surface, and the mass flow rate through the nozzle. Testing will be performed on a range of regolith simulants of varying composition and will also include instrumented impingement plate tests in place of regolith simulant to characterize gas-only plume physics. Novel high-speed visual diagnostics will capture temporal data on crater formation and ejecta dynamics, and planar laser-induced fluorescence diagnostics will capture plume structure and behavior. This paper will present an overview of the data collected during this test – for both the cratering and ejecta testing and the gas-only plume physics testing. Emphasis will be placed on trends, effects, and interactions observed in the data across the test parameter space.

Chad J. Eberhart↗

Series-Bosch Technology for Oxygen Recovery During Lunar or Martian Surface Missions

Long‐duration surface missions to the Moon or Mars will require life support systems that maximize resource recovery to minimize resupply from Earth. To address this need, NASA previously proposed a Series‐Bosch (S‐Bosch) oxygen recovery system, based on the Bosch process, which can theoretically recover 100% of the oxygen from metabolic carbon dioxide. Bosch processes have the added benefits of the potential to recover oxygen from atmospheric carbon dioxide and the use of regolith materials as catalysts, thereby eliminating the need for catalyst resupply from Earth. In 2012, NASA completed an initial design for an S‐Bosch development test stand that incorporates two catalytic reactors in series including a Reverse Water‐Gas Shift (RWGS) Reactor and a Carbon Formation Reactor (CFR). In 2013, fabrication of system components, with the exception of a CFR, and assembly of the test stand was initiated. Stand‐alone testing of the RWGS reactor was completed to compare performance with design models. Continued testing of Lunar and Martian regolith simulants provided sufficient data to design a CFR intended to utilize these materials as catalysts. Finally, a study was conducted to explore the possibility of producing bricks from spend regolith catalysts. The results of initial demonstration testing of the RWGS reactor, results of continued catalyst performance testing of regolith simulants, and results of brick material properties testing are reported. Additionally, design considerations for a regolith‐based CFR are discussed.

Abney, Morgan B.↗

Series-Bosch Technology for Oxygen Recovery During Lunar or Martian Surface Missions

Long-duration surface missions to the Moon or Mars will require life support systems that maximize resource recovery to minimize resupply from Earth. To address this need, NASA previously proposed a Series-Bosch (S-Bosch) oxygen recovery system, based on the Bosch process, which can theoretically recover 100% of the oxygen from metabolic carbon dioxide. Bosch processes have the added benefits of the potential to recover oxygen from atmospheric carbon dioxide and the use of regolith materials as catalysts, thereby eliminating the need for catalyst resupply from Earth. In 2012, NASA completed an initial design for an S-Bosch development test stand that incorporates two catalytic reactors in series including a Reverse Water-Gas Shift (RWGS) Reactor and a Carbon Formation Reactor (CFR). In 2013, fabrication of system components, with the exception of a CFR, and assembly of the test stand was initiated. Stand-alone testing of the RWGS reactor was completed to compare performance with design models. Continued testing of Lunar and Martian regolith simulants provided sufficient data to design a CFR intended to utilize these materials as catalysts. Finally, a study was conducted to explore the possibility of producing bricks from spent regolith catalysts. The results of initial demonstration testing of the RWGS reactor, results of continued catalyst performance testing of regolith simulants, and results of brick material properties testing are reported. Additionally, design considerations for a regolith-based CFR are discussed.

Abney, Morgan B.↗

GC/MS Method Development for Separating Lunar Volatile Ice Simulant Headspace Gases

Various investigators propose the lunar surface contains widely distributed volatiles, especially water- like species, i.e. OH and H2O. Surface volatiles are theorized to exist as a hydrated regolith layer, concentrated in extremely cold polar permanently shadowed regions (PSR), and/or solar wind implantation reservoirs in lunar glasses. The proposed sources of lunar surface volatiles range from cometary impacts, solar wind, or a supply present during moon formation. Future Artemis missions aim to collect and return the samples containing volatiles collected near lunar polar craters or PSRs. We, as advanced curation scientists, are responsible for developing techniques and methodologies for preserving returned sample integrity as much as possible. Pristine volatile-bearing samples are invaluable to the scientific community seeking to unravel the history of the solar system. Realistically, a sample will experience alteration during collection, transportation back to earth, and storage. The Planetary Exploration and Astromaterials Research Lab (PEARL) seeks to understand temperature and pressure effects on high-fidelity volatile-containing regolith simulants, the foundation for the future of cold curation. This abstract outlines the separation, identification, and quantification of headspace gases over volatile ice feed stock material using gas chromatography/mass spectrometry (GC/MS). Preliminary objectives concentrated on sample handling, reproducibility, and understanding the elution characteristics for each analyte. Initial GC/MS method development experiments utilized diluted static headspace sample preparation. Diluted samples were used because sampling headspace gases directly from a vial containing liquid analyte resulted in overloading of the column and detector. Overloading is evident based on chromatogram peak shapes and instrument contamination, or carry over, between experiments. A mixture of three alcohols were used for a majority of the sample handling and reproducibility studies. Reproducibility was tested via multiple users, calibration curves, and check standards. Stock solutions of condensed lunar volatile analytes included methanol, ammonia in methanol, hydrogen sulfide in water, and an equal volume mixture of methanol, ethanol, and isopropanol. Current samples use room air as the headspace sample matrix, however future experiments will incorporate an inert purge gas, such as argon or nitrogen. Three mL of each analyte solution were capped in separate 20 mL crimp top GC vials. Dilutions were carried out by removing an aliquot of headspace gases with a calibrated 1 mL gastight syringe and immediately transferring to a 20 mL capped crimp top vial. The GC/MS is a Thermo Fisher Trace 1310/ISQ 7000 with a TriPlus RSH autosampler and split/splitless injector module. The experiments outlined in this abstract use the following hardware: a 2.5 mL gastight headspace syringe tool, 1 mm ID x 78.5 mm length ultra-inert straight injection liner, and a TG-BondQ 30 m × 0.32 mm × 10 μm column. Various parameters, such as hardware selection and the temperature, pressure, and split ratio set points, continue to evolve as the overall experiment is refined. Diluted headspace chromatograms were collected for the individual stock solutions. Retention times, peak shapes, and mass spectra were evaluated and added to the data processing method for each molecule of interest. Figure 1 shows the total ion chromatograms for the three major lunar volatile simulant stock solutions: methanol, 7 N ammonia in methanol, and 0.4% hydrogen sulfide in water. Tailing peak shapes for ammonia (2.98 min rt) and water (4.06 min rt) indicate the molecules are not properly eluting from the selected column with the current separation method. Additionally, hydrogen sulfide and ammonia have overlapping peak windows, which could impact quantification. Ongoing experiments aim to address the peak shape and overlapping via the separation method and hardware selection. Sample preparation reproducibility experiments used stock solution containing equal volumes of a non- interactive mixture of methanol, ethanol, and isopropanol. Mass spectrum ion traces were used to identify and quantify all three alcohols. Peaks were automatically detected, identified, and integrated through the mass spectra detection and processing parameters. Calibration response curves and check standards were used to evaluate the validity of the sample preparation procedure. Figure 2 shows the methanol chromatogram peak area versus total headspace dilution volume transferred from the alcohol mixture vial. The calibration response curves and check standards validate sample preparation procedure. Continuing data analysis efforts are working towards correlating the peak area and instrument response factor to the headspace analyte concentration and condensed phase composition. Static headspace gas chromatography theory relies on Dalton’s law, Raoult’s law, Henry’s Law, and the Kolb and Ettre equation to associate peak area to the analyte composition in a non-ideal solution. Equation 1 is a simplified expression derived from the aforementioned theories. Future experiments involve liquid injections of the individual stock solutions, liquid and headspace analysis of various stock solution combinations, and the addition of regolith simulants to the mixtures. Temperature is another variable expected to affect reaction rates and will be explored.

Cecilia L. Amick↗

Abrasive Effects of Lunar Regolith on Material Wear for Long-Term Lunar Applications

Long-term operations on the Moon’s surface require materials that can withstand the harsh lunar environment. Lunar dust and regolith pose significant threats to the long-term durability of materials used in lunar applications. Lunar dust, easily perturbed and dispersed, adheres and abrades materials due to its rough and irregular grain morphology. More closely representing this abrasion action through experimental laboratory testing is critical in assessing the durability of potential lunar candidate materials used in mechanical, sensor, and human-based systems. In this study, the performance of materials using Taber abrasive wheels made from lunar regolith simulant was assessed and compared to results obtained using standard ceramic-based abrasion materials. The results highlight a difference in the abrasive wear rates between the lunar regolith simulant and the standard ceramic-based abrasive. Utilizing the mechanisms and testing capabilities of this two-body abrasive interaction leveraging regolith-based abrasives may more closely represent the interplay between materials and lunar dust, which is vital for assessing the long-term viability of materials for extended lunar missions. Improved lunar testing capabilities may also enhance evaluations of the long-term performance degradation of passive and active dust mitigation methods.

Zachary Stein↗

Hermes LunarG Executive Summary

Hermes LunarG is a flight-proven research platform that can measure the effects of lunar gravity on different types of astromaterials using Blue Origin's reusable sub-orbital flight system. Hermes LunarG is part of the Strata-1 family of experiments that leverages International Space Station (ISS) flight hardware to investigate particle dynamics. The platform is a single payload locker consisting of four clear, polycarbonate tubes containing different regolith simulant materials. Onboard the New Shephard, once lunar gravity conditions are achieved, the payload releases the simulants to move freely in the tubes. The payload will capture images and sensor data to illustrate the dust settling effects and behavior of lunar regolith simulant in this environment. Funded by NASA STMD (Space Technology Mission Directorate) GCD (Game Changing Development) Program, the project has been developed by NASA, T STAR (Texas Space Technology Applications and Research) and Texas A&M's SOAR (Sub-Orbital Astromaterial Research) team to deliver a platform that will further address gaps in dust mitigation and improve the understanding of regolith in lunar gravity.

regolith↗

Characterization of Minnesota lunar simulant for plant growth

Processing of lunar regolith into a plant growth medium is crucial in the development of a regenerative life support system for a lunar base. Plants, which are the core of such a system, produce food and oxygen for humans and, at the same time, consume carbon dioxide. Because of the scarcity of lunar regolith, simulants must be used to infer its properties and to develop procedures for weathering and chemical analyses. The Minnesota Lunar Simulant (MLS) has been identified to date as the best available simulant for lunar regolith. Results of the dissolution studies reveal that appropriately fertilized MLS can be a suitable medium for plant growth. The techniques used in conducting these studies can be extended to investigate the suitability of actual lunar regolith as a plant growth medium. Dissolution experiments were conducted using the MLS to determine its nutritional and toxicity characteristics for plant growth and to develop weathering and chemical analysis techniques. Two weathering regimes, one with water and one with dilute organic acids simulating the root rhizosphere microenvironment, were investigated. Elemental concentrations were measured using inductively-coupled-plasma (ICP) emission spectrometry and ion chromatography (IC). The geochemical speciation model, MINTEQA2, was used to determine the major solution species and the minerals controlling them. Acidification was found to be a useful method for increasing cation concentrations to meaningful levels. Initial results indicate that MLS weathers to give neutral to slightly basic solutions which contain acceptable amounts of the essential elements required for plant nutrition (i.e., potassium, calcium, magnesium, sulfur, zinc, sodium, silicon, manganese, copper, chlorine, boron, molybdenum, and cobalt). Elements that need to be supplemented include carbon, nitrogen, and perhaps phosphorus and iron. Trace metals in solution were present at nontoxic levels.

Oglesby, James P.↗

Impact of Drilling Operations on Lunar Volatiles Capture: Thermal Vacuum Tests

In Situ Resource Utilization (ISRU) enables future planetary exploration by using local resources to supply mission consumables. This idea of 'living off the land' has the potential to reduce mission cost and risk. On the moon, water has been identified as a potential resource (for life support or propellant) at the lunar poles, where it exists as ice in the subsurface. However, the depth and content of this resource has yet to be confirmed on the ground; only remote detection data exists. The upcoming Resource Prospector mission (RP) will 'ground-truth' the water using a rover, drill, and the RESOLVE science package. As the 2020 planned mission date nears, component level hardware is being tested in relevant lunar conditions (thermal vacuum). In August 2014 a series of drilling tests were performed using the Honeybee Robotics Lunar Prospecting Drill inside a 'dirty' thermal vacuum chamber at the NASA Glenn Research Center. The drill used a unique auger design to capture and retain the lunar regolith simulant. The goal of these tests was to investigate volatiles (water) loss during drilling and sample transfer to a sample crucible in order to validate this regolith sampling method. Twelve soil samples were captured over the course of two tests at pressures of 10(exp-5) Torr and ambient temperatures between -80C to -20C. Each sample was obtained from a depth of 40 cm to 50 cm within a cryogenically frozen bed of NU-LHT-3M lunar regolith simulant doped with 5 wt% water. Upon acquisition, each sample was transferred and hermetically sealed inside a crucible. The samples were later baked out to determine water wt% and in turn volatile loss by following ASTM standard practices. Of the twelve tests, four sealed properly and lost an average of 30% of their available water during drilling and transfer. The variability in the results correlated well with ambient temperature (lower the temperature lower volatiles loss) and the trend agreed with the sublimation rates for the same temperature. Moisture retention also correlated with quantity of sample: a larger amount of material resulted in less water loss. The drilling process took an average of 10 minutes to capture and transfer each sample. The drilling power was approximately 20 Watt with a Weight on Bit of approximately 30 N. The bit temperature indicated little heat input into formation during the drilling process.

drilling↗

Structural, Physical, and Compositional Analysis of Lunar Simulants and Regolith

Relative to the prior manned Apollo and unmanned robotic missions, planned Lunar initiatives are comparatively complex and longer in duration. Individual crew rotations are envisioned to span several months, and various surface systems must function in the Lunar environment for periods of years. As a consequence, an increased understanding of the surface environment is required to engineer and test the associated materials, components, and systems necessary to sustain human habitation and surface operations. The effort described here concerns the analysis of existing simulant materials, with application to Lunar return samples. The interplay between these analyses fulfills the objective of ascertaining the critical properties of regolith itself, and the parallel objective of developing suitable stimulant materials for a variety of engineering applications. Presented here are measurements of the basic physical attributes, i.e. particle size distributions and general shape factors. Also discussed are structural and chemical properties, as determined through a variety of techniques, such as optical microscopy, SEM and TEM microscopy, Mossbauer Spectroscopy, X-ray diffraction, Raman microspectroscopy, inductively coupled argon plasma emission spectroscopy and energy dispersive X-ray fluorescence mapping. A comparative description of currently available stimulant materials is discussed, with implications for more detailed analyses, as well as the requirements for continued refinement of methods for simulant production.

Greenberg, Paul↗

Combustion Joining of Regolith Tiles for In-Situ Fabrication of Launch/Landing Pads on the Moon and Mars

To mitigate dust problems during launch/landing operations in lunar and Mars missions, it is desired to build solid pads on the surface. Recently, strong tiles have been fabricated from lunar regolith simulants using high-temperature sintering. The present work investigates combustion joining of these tiles through the use of exothermic intermetallic reactions. Specifically, nickel/aluminum (1:1 mole ratio) mixture was placed in a gap between the tiles sintered from JSC-1A lunar regolith simulant. Upon ignition by a laser, a self-sustained propagation of the combustion front over the mixture occurred. Joining was improved with increasing the tile thickness from 6.3 mm to 12.7 mm. The temperatures sufficient for melting the glass phase of JSC-1A were recorded for 12.7-mm tiles, which explains the observed better joining.

Ferguson, Robert E.↗

Combustion Joining of Regolith Tiles for In-Situ Fabrication of Launch/Landing Pads on the Moon and Mars

To mitigate dust problems during launch-landing operations in lunar and Mars missions, it is desired to build solid pads on the surface. Recently, strong tiles have been fabricated from lunar regolith simulants using high-temperature sintering. The present work investigates combustion joining of these tiles through the use of exothermic intermetallic reactions. Specifically, nickel aluminum (1:1 mole ratio) mixture was placed in a gap between the tiles sintered from JSC-1A lunar regolith simulant. Upon ignition by a laser, a self-sustained propagation of the combustion front over the mixture occurred. Joining was improved with increasing the tile thickness from 6.3 mm to 12.7 mm. The temperatures sufficient for melting the glass phase of JSC-1A were recorded for 12.7-mm tiles, which explains the observed better joining.

Ferguson, Robert E.↗

Multiphysics Modeling for Dimensional Analysis of a Self-Heated Molten Regolith Electrolysis Reactor for Oxygen and Metals Production on the Moon and Mars

The technology of direct electrolysis of molten lunar regolith to produce oxygen and molten metal alloys has progressed greatly in the last few years. The development of long-lasting inert anodes and cathode designs as well as techniques for the removal of molten products from the reactor has been demonstrated. The containment of chemically aggressive oxide and metal melts is very difficult at the operating temperatures ca 1600 C. Containing the molten oxides in a regolith shell can solve this technical issue and can be achieved by designing a self-heating reactor in which the electrolytic currents generate enough Joule heat to create a molten bath. In a first phase, a thermal analysis model was built to study the formation of a melt of lunar basaltic regolith irradiated by a focused solar beam This mode of heating was selected because it relies on radiative heat transfer, which is the dominant mode of transfer of energy in melts at 1600 C. Knowing and setting the Gaussian-type heat flux from the concentrated solar beam and the phase and temperature dependent thermal properties, the model predicts the dimensions and temperature profile of the melt. A validation of the model is presented in this paper through the experimental formation of a spherical cap melt realized by others. The Orbitec/PSI experimental setup uses an 3.6-cm diameter concentrated solar beam to create a hemispheric melt in a bed of lunar regolith simulant contained in a large pot. Upon cooling, the dimensions of the vitrified melt are measured to validate the thermal model. In a second phase, the model is augmented by multiphysics components to compute the passage of electrical currents between electrodes inserted in the molten regolith. The current through the melt generates Joule heating due to the high resistivity of the medium and this energy is transferred into the melt by conduction, convection and primarily by radiation. The model faces challenges in two major areas, the change of phase as temperature increases, and the dominance of radiative heat flux as heat transfer mechanism within the melt the change of phase concerns the regolith itself which is present in states ranging from a fine grain regolith with low thermal conductivity and low density to a vitrified melt with much higher thermal conductivity, and higher density. As the regolith is heated, it starts to soften around 1300 C the melt iS very viscous and evolving gas bubbles out in thick, lava-like fashion. By 1600 C the regolith is completely melted and the viscosity is low The second challenge resides in the proper modeling of the radiative heat flux requiring the addition of the computing-demanding radiative-heat-transfer function to the general heat transfer equation. The model Includes temperature-dependent properties (density, thermal conductivity, heat capacity, and viscosity, and absorption coefficients) and solves the radiative heat flux equation assuming gray (fine grains) and semi-transparent (melt) media and using an absorption coefficient spectral found in the literature for terrestrial minerals similar in composition to those of lunar regolith simulant

Dominguez, Jesus A.↗

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.↗

Carbothermal Reduction Demonstration (CaRD)

Introduction: Lunar regolith is approximately 45% oxygen by mass. The majority of the oxygen is bound in silicate minerals. The carbothermal reduction process has been proven to be effective at removing oxygen from lunar regolith simulants. The Carbothermal Reduction Demonstration (CaRD) project aims to increase the Technology Readiness Level (TRL) of a combined solar concentrator and carbothermal reduction systemin order to demonstrate this technology on the lunar surface. The CaRD project is divided into two design cycles, a brass board and prototype. The status of both design cycles will be discussed, as well as concepts for how this technology can be applied to the Artemis program in the future. Brassboard Vacuum Test: For the brassboard demonstration, a 2 kW Nd-YAG laser was used to heat lunar regolith simulant within a carbothermal reactor developed by Sierra Space. The reactor was placed inside of a 15 ft thermal vacuum chamber at the Johnson Space Center. The resulting reaction products were analyzed using both a gas chromotograph and mass spectrometer provided by Kennedy Space Center. Thermal data was also collected. Prototype Design: For the prototype, the CaRD team will perform another thermal vacuum test at JSC using the same interfaces and assets developed for the brassboard but will test a new carbothermal reactor design that Sierra Space is developing through the Carbothermal Oxygen Production Reactor (COPR) Tipping Point project that will include a means to autonomously move regolith in and out of the reactor. In addition, a deployable solar concentrator is being developed by Glenn Research Center using mirrors produced by Carbon Mirror Applications. The solar concentrator will be used to deliver solar energy into a carbothermal reactor to melt regolith and extract oxygen. Avionics and software for the concentrator are being developed by Kennedy Space Center. Future Concepts: An ongoing task within the CaRD project is to update models that can be used to determine the mass, power, and size of In-Situ Resource Utilization concepts at various scales. These models can now be used to analyze alternatives for future applications based on the latest available data.

Aaron Paz↗

Carbothermal Reduction Demonstration: Laser Driven Reaction in a Thermal-Vacuum Environment and Project Status

Introduction: Lunar regolith is approximately 45% oxygen by mass. The majority of the oxygen is bound in silicate minerals. The carbothermal reduction process has been proven to be effective at removing oxygen from lunar regolith simulants [1]. The Carbothermal Reduction Demonstration (CaRD) project aims to increase the Technology Readiness Level (TRL) of a combined solar concentrator and carbothermal reduction systemin order to demonstrate this technology on the lunar surface. The CaRD project is divided into two design cycles, a brass board and prototype. The status of both design cycles will be discussed, as well as concepts for how this technology can be applied to the Artemis program in the future. Brassboard Vacuum Test: For the brassboard demonstration, a 2 kW Nd-YAG laser was used to heat lunar regolith simulant within a carbothermal reactor developed by Sierra Space. The reactor was placed inside of a 15 ft thermal vacuum chamber at the Johnson Space Center. The resulting reaction products were analyzed using both a gas chromotograph and mass spectrometer provided by Kennedy Space Center. Thermal data was also collected. Prototype Design: For the prototype, the CaRD team will perform another thermal vacuum test at JSC using the same interfaces and assets developed for the brassboard but will test a new carbothermal reactor design that Sierra Space is developing through the Carbothermal Oxygen Production Reactor (COPR) Tipping Point project that will include a means to autonomously move regolith in and out of the reactor. In addition, a deployable solar concentrator is being developed by Glenn Research Center using mirrors produced by Carbon Mirror Applications. The solar concentrator will be used to deliver solar energy into a carbothermal reactor to melt regolith and extract oxygen. Avionics and software for the concentrator are being developed by Kennedy Space Center. Future Concepts: An ongoing task within the CaRD project is to update models that can be used to determine the mass, power, and size of In-Situ Resource Utilization concepts at various scales. These models can now be used to analyze alternatives for future applications based on the latest available data.

A J Paz↗

Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)

The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.

Adam Johnson↗