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Development of Long-Lifetime Pulsed Gas Valves for Pulsed Electric Thrusters

It is advantageous for gas-fed pulsed electric thrusters to employ pulsed valves so propellant is only flowing to the device during operation. The propellant utilization of the thruster will be maximized when all the gas injected into the thruster is acted upon by the fields produced by the electrical pulse. Gas that is injected too early will diffuse away from the thruster before the electrical pulse can act to accelerate the propellant. Gas that is injected too late will miss being accelerated by the already-completed electrical pulse. As a consequence, the valve must open quickly and close equally quickly, only remaining open for a short duration. In addition, the valve must have only a small amount of volume between the sealing body and the thruster so the front and back ends of the pulse are as coincident as possible with the valve cycling, with very little latent propellant remaining in the feed lines after the valve is closed. For a real mission of interest, a pulsed thruster can be expected to pulse at least 10(exp 10) - 10(exp 11) times, setting the range for the number of times a valve must open and close. The valves described in this paper have been fabricated and tested for operation in an inductive pulsed plasma thruster (IPPT) for in-space propulsion. In general, an IPPT is an electrodeless space propulsion device where a capacitor is charged to an initial voltage and then discharged, producing a high-current pulse through a coil. The field produced by this pulse ionizes propellant, inductively driving current in a plasma located near the face of the coil. Once the plasma is formed, it can be accelerated and expelled at a high exhaust velocity by the electromagnetic Lorentz body force arising from the interaction of the induced plasma current and the magnetic field produced by the current in the coil. The valve characteristics needed for the IPPT application require a fast-acting valve capable of a minimum of 10(exp 10) valve actuation cycles. Since even 10(exp 9) cycles is well above anything demonstrated, this lower value was selected as the design point for the present work. The valve seal must remain leak-tight throughout operation, and the body must maintain a low internal leakage at relatively high operating temperatures. The full set of design requirements used for this program are summarized in Table 1. In this work, we describe two pulsed gas valves that have been fabricated to have long lifetime and demonstrate the characteristics listed above. The first is a miniaturized, conventional electromagnet-based valve while the second is a piezoelectric-based valve design. The conventional valve, shown in Fig. 1, is opened by use of a solenoid electromagnetic actuator. When current is applied to the solenoid coil, magnetic forces pull the plunger away from the valve seat, allowing fluid to flow through the valve. Removal of electrical current permits the spring and fluid pressure to seat the plunger, halting the flow of fluid. The valve body is fabricated from 304L corrosion resistant steel (CRES) and while the parts that form the magnetic circuit are fabricated from 430 CRES. This material does not have optimum magnetic properties, but its corrosion resistance permits incorporation into a design without requiring an additional plating process. A viton O-ring compound (Parker V0884-75), selected for its mechanical strength at elevated temperatures, was used for the valve seat seal. The design was based solely on the use of analytical sizing calculations, as opposed to a more rigorous finite element analysis. While this valve is small and relatively lightweight, it does not represent a design that is optimized for mass and/or a given volume envelope. The piezoelectric valve is a "puller" valve design. Applying a voltage to the piezo crystal causes it to elongate and pull a pintle off the seat, opening the valve. The valve seal consists of the pintle with an external, spherically-formed tip fabricated from Inconel 625 and the seat fabricated from Inconel 718 and possessing a spherical surface that permits the pintle to align with the valve body centerline after each cycle, maintaining the circumferential metal-on-metal seal. The contact stress on the valve pintle is expected in the worst case to be 96.5 MPa (14 ksi), which is well below the work hardening value of 413.7 MPa (60 ksi) for Inconel 615. Results presented in this work will compare the performance of each valve, both to each other and to the valve design requirements given in Table 1. In general, both valves meet all the performance envelope requirements, but the piezoelectric valve consumes considerably less power and has a faster response time over the conventional solenoid-driven valves.

Burkhardt, Wendel M.↗

Simulation of Mini-Magnetospheric Plasma Propulsion (M2P2) Interacting with an External Plasma Wind

Substantial progress has been made over the last year in the development of the laboratory Mini-Magnetospheric Plasma Propulsion (M2P2) prototype. The laboratory testing has shown that that the plasma can be produced at high neutral gas efficiency, at high temperatures (a few tens of eV) with excellent confinement up to the point where chamber wall interactions dominate the physics. This paper investigates the performance of the prototype as it is opposed by an external plasma acting as a surrogate for the solar wind. The experiments were performed in 5ft diameter by 6ft long vacuum chamber at the University of Washington. The solar wind source comprised of a 33 kWe arc jet attached to a 200 kWe inductively generated plasma source. The dual plasma sources allow the interaction to be studied for different power levels, shot duration and production method. It is shown that plasma from the solar wind source (SWS) is able to penetrate the field of the M2P2 magnetic when no plasma is present. With operation of the M2P2 plasma source at only 1.5 kWe, the penetration of the SWS even at the highest power of operation at 200 kWe is stopped. This deflection is shown to be greatly enhanced over that produced by the magnet alone. In addition it is shown that with the presence of the SWS, M2P2 is able to produce enhanced magnetized plasma production out to at least 10 magnet radii where the field strength is only marginally greater than the terrestrial field. The results are consistent with the initial predictions that kWe M2P2 systems would be able to deflect several hundred kWe plasma winds to produce enhanced propulsion for a spacecraft.

Winglee, R. M.↗

Rapid Cycling CO2 and H2O Removal System for EMU

NASA's planned future missions set stringent demands on the design of the Portable Life Support Systems (PLSS), requiring dramatic reductions in weight, decreased reliance on supplies and greater flexibility on the types of missions. Use of regenerable systems that reduce weight and volume of the EMU is of critical importance to NASA, both for low orbit operations and for long duration manned missions. The CO2 and humidity control unit in the existing PLSS design is relatively large, since it has to remove 8 hours worth of CO2. If the sorbent regeneration can be carried out during the extravehicular activity (EVA) with a relatively high regeneration frequency, the size of the sorbent canister and weight can be significantly reduced. TDA Research, Inc. (TDA) is developing a compact, regenerable sorbent-based system to control CO2 and humidity in the space suit ventilation loop. The sorbent can be regenerated using space vacuum during the EVA, eliminating all duration-limiting elements in the life support system. This paper summarizes the results of the sorbent development and testing, and evaluation efforts. The results of a preliminary system analysis are also included, showing the size and volume reductions provided by the new system.

Alptekin, Gokhan↗

Validation of Lithium-ion cell technology for JPL's 2003 Mars Exploration Rover Mission

n early 2004 JPL successfully landed two Rovers, named Spirit and Opportunity, on the surface of Mars after traveling >300 million miles over a 6-7 month period. In order to operate for extended duration on the surface of Mars, both Rovers are equipped with rechargeable Lithium-ion batteries, which were designed to aid in the launch, correct anomalies during cruise, and support surface operations in conjunction with a triple-junction deployable solar arrays. The requirements of the Lithium-ion battery include the ability to provide power at least 90 sols on the surface of Mars, operate over a wide temperature range (-20 C to +40 C), withstanding long storage periods (e.g., cruise period), operate in an inverted position, and support high currents (e.g., firing pyro events). In order to determine the viability of Lithium-ion technology to meet these stringent requirements, a comprehensive test program was implemented aimed at demonstrating the performance capability of prototype cells fabricated by Lithion, Inc. (Yardney Technical Products, Inc.). The testing performed includes, determining the (a) room temperature cycle life, (b) pulse capability as a function of temperature, (e) self-discharge and storage characteristics mission profile capability, (f) cycle life under mission simulation conditions, (g) impedance characteristics, (h) impact of cell orientation, and (i) performance in 8-cell engineering batteries. As will be discussed, the Lithium-ion prototype cells and batteries were demonstrated to meet, as well as, exceed the requirements defined by the mission.

2003 Mars Exploration Rover (MER)↗

Definition study for an advanced cosmic ray experiment utilizing the long duration exposure facility

To achieve the goals of cosmic ray astrophysics, an ultraheavy cosmic ray experiment on an LDEF reflight should be in an orbit with high inclination (approximately 57 deg) at approximately 230 nm for approximately 2 years near solar minimum (approximately 1986). It should fill 61 trays. Each tray should contain 4 modules of total active area 0.7 sq m, with a thermal blanket, thermal labyrinth mounts, aluminum honeycomb mechanical support, and total weight approximately 100 kg. Each module should contain interleaved CR39, Lexan, and thin copper sheets plus one event-thermometer canned in a thin metal cannister sealed with approximately 0.2 atm dry O2. The CR39 and Lexan should be manufactured to specifications and the sheet copper rolled to specifications. The event-thermometer should be a stiffened CR39 sheet that slides via bimetal strips relative to fixed CR39 sheet so that stack temperature can be read out for each event. The metal cannister can be collapsed at launch and landing, capturing the sliding assembly to prevent damage. An engineering study should be made of a prototype LDEF tray; this will include thermal and mechanical tests of detectors and the event thermometer.

Price, P. B.↗

Phase Separation in Lean Grade Duplex Stainless Steel 2101

The use of duplex stainless steels (DSS) in nuclear power generation systems is limited by thermal instability that leads to embrittlement in the temperature range of 204°C - 538°C. New lean grade alloys, such as 2101, offer the potential to mitigate these effects. Thermal embrittlement was quantified through impact toughness and hardness testing on samples of alloy 2101 after aging at 427°C for various durations (1-10,000 hours). Additionally, atom probe tomography (APT) was utilized in order to observe the kinetics of α-α’ separation and G-phase formation. Mechanical testing and APT data for two other DSS alloys, 2003 and 2205 were used as a reference to 2101. The results show that alloy 2101 exhibits superior performance compared to the standard grade DSS alloy, 2205, but inferior to the lean grade alloy, 2003, in mechanical testing. APT data demonstrates that the degree of α-α’ separation found in alloy 2101 closely resembles that of 2205, and greatly exceeds 2003. Additionally, contrary to what was observed in 2003, 2101 demonstrated G-phase like precipitates after long aging times, though precipitates were not as abundant as was observed in 2205.

36 MATERIALS SCIENCE↗

Embedded High-Temperature Sensors: Enhancing Thermoelectrical Performance with Refractory Composites Gradient Layers

To monitor the stability of various energy and manufacturing systems, sensors capable of operating at temperatures exceeding 1000 °C in diverse environments for extended durations are essential. However, under harsh conditions, degradation of sensing materials is a concern that can be controlled by embedding the sensors into refractory oxides. Doped-LaCrO3 based composites are excellent candidates for high-temperature sensing applications due to their good thermoelectrical properties. However, chemical reactivity between the conductive phase and the refractory oxides can decrease the performance of the sensors. In this work, it was devised gradient-type protective layers safeguarding conductive phases within embedded thermocouples, which were fabricated and characterized by X-Ray Diffraction for phase development analysis, Scanning Electron Microscopy and Energy-dispersive X-ray spectroscopy for microstructure and cationic interdiffusion kinetics, long-term thermoelectric testing was completed up to 1400 °C. The enhanced performance of these novel sensors addresses a critical limitation, rendering them viable for long-term high-temperature applications.

20 FOSSIL-FUELED POWER PLANTS↗

Advanced Life Support Project: Crop Experiments at Kennedy Space Center

Crop production systems provide bioregenerative technologies to complement human crew life support requirements on long duration space missions. Kennedy Space Center has lead NASA's research on crop production systems that produce high value fresh foods, provide atmospheric regeneration, and perform water processing. As the emphasis on early missions to Mars has developed, our research focused on modular, scalable systems for transit missions, which can be developed into larger autonomous, bioregenerative systems for subsequent surface missions. Components of these scalable systems will include development of efficient light generating or collecting technologies, low mass plant growth chambers, and capability to operate in the high energy background radiation and reduced atmospheric pressures of space. These systems will be integrated with air, water, and thermal subsystems in an operational system. Extensive crop testing has been done for both staple and salad crops, but limited data is available on specific cultivar selection and breadboard testing to meet nominal Mars mission profiles of a 500-600 day surface mission. The recent research emphasis at Kennedy Space Center has shifted from staple crops, such as wheat, soybean and rice, toward short cycle salad crops such as lettuce, onion, radish, tomato, pepper, and strawberry. This paper will review the results of crop experiments to support the Exploration Initiative and the ongoing development of supporting technologies, and give an overview of capabilities of the newly opened Space Life Science (SLS) Lab at Kennedy Space Center. The 9662 square m (104,000 square ft) SLS Lab was built by the State of Florida and supports all NASA research that had been performed in Hanger-L. In addition to NASA research, the SLS Lab houses the Florida Space Research Institute (FSRI), responsible for co-managing the facility, and the University of Florida (UF) has established the Space Agriculture and Biotechnology Research and Education (SABRE) Center with several faculty.

Sager, John C.↗

Rapid Analysis, Self-Calibrating Array for Air Monitoring

Human space missions have critical needs for monitoring and control for life support systems. These systems have monitoring needs that include feedback for closed loop processes and quality control for environmental factors. Sensors and monitoring technologies assure that the air environment and water supply for the astronaut crew habitat fall within acceptable limits, and that the life support system is functioning properly and efficiently. The longer the flight duration and the more distant the destination, the more critical it becomes to have carefully monitored and automated control systems for life support. Past experiments with the JPL ENose have demonstrated a lifetime of the sensor array, with the software, of around 18 months. The lifetime of the calibration, for some analytes, was as long as 24 months. We are working on a sensor array and new algorithms that will include sensor response time in the analysis. The preliminary array analysis for two analytes shows that the analysis time, of an event, can be dropped from 45 minutes to less than10 minutes and array training time can be cut substantially. We will describe the lifetime testing of an array and show lifetime data on individual sensors. This progress will lead to more rapid identification of analytes, and faster training time of the array.

Self Calibrating↗

Development of an Indexing Media Filtration System for Long Duration Space Missions

The effective maintenance of air quality aboard spacecraft cabins will be vital to future human exploration missions. A key component will be the air cleaning filtration system which will need to remove a broad size range of particles including skin flakes, hair and clothing fibers, other biological matter, and particulate matter derived from material and equipment wear. In addition, during surface missions any extraterrestrial planetary dust, including dust generated by near-by ISRU equipment, which is tracked into the habitat will also need to be managed by the filtration system inside the pressurized habitat compartments. An indexing media filter system is being developed to meet the demand for long-duration missions that will result in dramatic increases in filter service life and loading capacity, and will require minimal crew involvement. These features may also benefit other closed systems, such as submarines, and remote location terrestrial installations where servicing and replacement of filter units is not practical. The filtration system consists of three stages: an inertial impactor stage, an indexing media stage, and a high-efficiency filter stage, packaged in a stacked modular cartridge configuration. Each stage will target a specific range of particle sizes that optimize the filtration and regeneration performance of the system. An 1/8th scale and full-scale prototype of the filter system have been fabricated and have been tested in the laboratory and reduced gravity environments that simulate conditions on spacecrafts, landers and habitats. Results from recent laboratory and reducegravity flight tests data will be presented.

Filtration↗

Temporal Changes in Astronauts’ Muscle and Cardiorespiratory Physiology Before, During, and After Spaceflight

Background: NASA’s planned space exploration missions will require astronauts to safely perform extravehicular activity (EVA) and to safely egress vehicles in a variety of landing scenarios. Prolonged exposure to spaceflight can diminish tolerance for physical activity, decrease cardiovascular and sensorimotor function, cause loss of bone mineral density, as well as reduced muscle mass and strength. Although exercise can mitigate these spaceflight-induced physiological decrements, little is known regarding the time-course of changes in muscle and aerobic performance during spaceflight. Furthermore, these exercise countermeasures are not fully protective. For example, maximal aerobic capacity (VO2pk), lower body muscle cross-sectional area, and strength decrease by about 10% to 15% after short- (≈14 days) and long-duration (≈6 months) missions on the International Space Station (ISS). Future space missions longer in duration and further from Earth will employ exploration vehicles that will have exercise hardware with less robust and more constrained exercise capabilities than of those available on the ISS. Thus, countermeasures will need to be optimized to protect crew health and performance on exploration-class missions lasting up to 3 years. This requires a more detailed understanding of the dynamic effects of spaceflight on human health and performance, the ability of exercise to protect against this deconditioning, and the interaction of exercise with interrelated factors like nutrition, sleep, and environmental conditions. Methods: We will use standardized research and medical testing protocols previously validated in 1g and microgravity to quantify the time course and the inter-individual variability of changes in physical performance, including cardiorespiratory fitness and muscle strength and endurance, before, during, and after spaceflight missions lasting 2 months, 6 months, and 1 year. Additionally, we will use an extrapolation model to predict changes associated with multi-year exploration missions. Additionally, we will monitor in-flight exercise, nutrition, and sleep using in-flight assessment tools. Significance: Our testing protocols will provide valuable information for determining time course of change and the interindividual variability of spaceflight-induced deconditioning of aerobic capacity and muscle strength and endurance over the course of spaceflight missions up to and beyond 1 year. This information will be vital to assess whether humans can be physically ready for deep space exploration, such as on a mission to Mars, using current technology, or if additional mitigation strategies are necessary.

N Strock↗

Partial analysis of experiment LDEF A-0114

Due to delays in manifesting the return of the Long Duration Exposure Facility from space, attention was concentrated on extracting the maximum information from the EIOM-2 (oxygen interaction with materials experiment) flown on STS-8 in September 1983. An analysis was made of the optical surfaces exposed during that flight and an assessment made of the effect of the 5 eV atomic oxygen upon their physical and chemical properties. The surfaces studied were of two types: high-purity thin films sputtered or evaporated onto 2.54-cm diam lambda/20 fused silica optical flats, and highly polished bulk samples. Rapid etching of carbon and carbonaceous surfaces was observed with polycarbonate CR-39 showing the largest etch of any substrate flown and measured. Of the metals tested, only osmium and silver showed large effects, the former being heavily etched and the later forming a very thick layer of oxide. The first measurable effects on iridium, aluminum, nickel, tungsten and niobium thin films are reported.

Gregory, J. C.↗

Development of a verification program for deployable truss advanced technology

Use of large deployable space structures to satisfy the growth demands of space systems is contingent upon reducing the associated risks that pervade many related technical disciplines. The overall objectives of this program was to develop a detailed plan to verify deployable truss advanced technology applicable to future large space structures and to develop a preliminary design of a deployable truss reflector/beam structure for use a a technology demonstration test article. The planning is based on a Shuttle flight experiment program using deployable 5 and 15 meter aperture tetrahedral truss reflections and a 20 m long deployable truss beam structure. The plan addresses validation of analytical methods, the degree to which ground testing adequately simulates flight and in-space testing requirements for large precision antenna designs. Based on an assessment of future NASA and DOD space system requirements, the program was developed to verify four critical technology areas: deployment, shape accuracy and control, pointing and alignment, and articulation and maneuvers. The flight experiment technology verification objectives can be met using two shuttle flights with the total experiment integrated on a single Shuttle Test Experiment Platform (STEP) and a Mission Peculiar Experiment Support Structure (MPESS). First flight of the experiment can be achieved 60 months after go-ahead with a total program duration of 90 months.

Dyer, Jack E.↗

Location of planar targets in three space from monocular images

Many pieces of existing and proposed space hardware that would be targets of interest for a telerobot can be represented as planar or near-planar surfaces. Examples include the biostack modules on the Long Duration Exposure Facility, the panels on Solar Max, large diameter struts, and refueling receptacles. Robust and temporally efficient methods for locating such objects with sufficient accuracy are therefore worth developing. Two techniques that derive the orientation and location of an object from its monocular image are discussed and the results of experiments performed to determine translational and rotational accuracy are presented. Both the quadrangle projection and elastic matching techniques extract three-space information using a minimum of four identifiable target points and the principles of the perspective transformation. The selected points must describe a convex polygon whose geometric characteristics are prespecified in a data base. The rotational and translational accuracy of both techniques was tested at various ranges. This experiment is representative of the sensing requirements involved in a typical telerobot target acquisition task. Both techniques determined target location to an accuracy sufficient for consistent and efficient acquisition by the telerobot.

Cornils, Karin↗

Degradation of optical components in a space environment

The objective of the Phillips Laboratory (PL) Long Duration Exposure Facility (LDEF) experiment is to determine the adverse effects of the natural space environment on laser optical component and coating materials. The LDEF experiment provides a unique opportunity for the study of optical material response to an extended low earth orbit space exposure. The PL samples consist of 10 sets of the six materials each. The materials are uncoated fused silica, magnesium fluoride coated fused silica, uncoated molybdenum, molybdenum coated with chromium, silver and thorium fluoride, diamond turned copper, and diamond turned nickel plated copper. Performance degradation will be correlated to establish trends between sample location, duration of exposure, atomic oxygen exposure and other space environmental conditions. This paper discusses the results of the tests thus far performed on the LDEF samples and the plans for the future.

Dehainaut, Linda L.↗

Midodrine as a Countermeasure to Orthostatic Hypotension Immediately After Space Shuttle Landing

Midodrine prevents post-space flight orthostatic intolerance when testing is conducted in a controlled laboratory setting within 2-4 hours after Space Shuttle landing. It is unknown if midodrine is as effective during re-entry and immediately following landing. METHODS: Cardiovascular responses to 10 minutes of 80 head-up tilt in five male astronauts were compared before and immediately after Space Shuttle missions. Preflight tests were conducted in the Johnson Space Center Cardiovascular Laboratory without midodrine. Post-flight testing was performed in the Crew Transport Vehicle on the Space Shuttle runway within 60 minutes of landing; midodrine was self-administered before re-entry. Survival analysis was performed (Gehan-Breslow test) to compare presyncope rates pre- to post-flight. Cardiovascular responses (last minute standing minus supine) to tilt before and after space flight were compared using paired t-tests. RESULTS: Midodrine did not prevent post-flight orthostatic hypotension in two of the five astronauts, but the rate of presyncope across the group did not increase (p=0.17) from pre- to post-flight. Also, although the change in heart rate from supine to the last minute of standing was not affected by space flight, systolic blood pressure decreased more (p=0.05) and diastolic blood pressure tended to decrease (p=0.08) after space flight. CONCLUSIONS: Accurate interpretation of the current results requires that similar data be collected in control subjects (without midodrine) on the CTV. However, drug interaction concerns with commonly used anti-emetics and potentiation of prolonged QTc intervals observed in long duration astronauts make the routine use of midodrine for immediate post-flight orthostatic hypotension unlikely. 2

Platts, Steven H.↗

High Performance Rotating Detonation Rocket Engine for Mars Interplanetary Transport

NASA has successfully evaluated the performances and survivability of two additively manufactured (AM) continuously rotating detonation cycle rocket engine (RDRE) thrust chambers. The AM hardware was subjected to long duration continuous detonative environments in excess of 100 seconds. Performance trends were directly compared to theory and similar scale constant pressure engines with identical propellants. The performance benefits of RDREs include higher combustion efficiency at a more compact design trade space, which allow advantages for future NASA missions. A major finding of this work is that the heat fluxes experienced are substantially higher than traditional liquid rocket engines at the same operating conditions. In addition, completion of combustion occurs rapidly in an annular geometry at ¼ that of the L* and L’ of an equivalent state-of-the-art thrust chamber. Finally, all hardware survived the extreme environments and achieved the major goal of the test project by demonstrating hot fire conditions with detonation modes up to 133 seconds in duration. Follow-on efforts funded by STMD Early Career Initiative (ECI) award are now focused on achieving higher performances than the previous designs and closing the remaining technology risks.

Thomas Teasley↗

New fixed-point mini-cell to investigate thermocouple drift in a high-temperature environment under neutron irradiation

Temperature measurements in the nuclear field require a high degree of reliability and accuracy. Despite their sheathed form, thermocouples subjected to nuclear radiations undergo changes due to radiation damage and transmutation that lead to significant EMF drift during long-term fuel irradiation experiment. For the purpose of a High Temperature Reactor fuel irradiation to take place in the High Flux Reactor Petten, a dedicated fixed-point cell was jointly developed by LNE-Cnam and JRC-IET. The developed cell to be housed in the irradiation rig was tailor made to quantify the thermocouple drift during the irradiation (about two year duration) and withstand high temperature (in the range 950 deg. C - 1100 deg. C) in the presence of contaminated helium in a graphite environment. Considering the different levels of temperature achieved in the irradiation facility and the large palette of thermocouple types aimed at surveying the HTR fuel pebble during the qualification test both copper (1084.62 deg. C) and gold (1064.18 deg. C) fixed-point materials were considered. The aim of this paper is to first describe the fixed-point mini-cell designed to be embedded in the reactor rig and to discuss the preliminary results achieved during some out of pile tests as much as some robustness tests representative of the reactor scram scenarios. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗