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Development of a Cold-Walled Molten Regolith Electrolysis Reactor for Lunar Oxygen Production

On the lunar surface, production of commodi-ties to support human presence, such as water, food and oxygen, and sustain the growth of a per-manent outpostwill likely require the use oflocal resources. The moon is covered almost entirely withfragmented oxide minerals known as regolithhundreds of meter thick.As a resource, it is rich in oxygen (> 42 wt.%) bound in a solid state with a variety of metals. The molten regolith electrolysis (MRE)reactor is a promising technology for the production of gaseous oxygen from the lunar reg-olithin a simple, single-stepreaction that requires minimalconsumable materials, produces oxygen and metals with high electrical efficiency and high yields from any regolithcomposition.This process involvesmelting regolith to~1600°C then electro-lyzing the molten pool to separate metal and oxy-gen ions that are then collected as liquid metal and gaseous oxygen at the respective electrodes. Lab-scale demonstrations of the MRE technology have previously reliedon external heating sources to bring the entirety of the reactor up to the operating temperaturewhich creates corrosive interfaces be-tween the molten regolith and the containment ma-terial in the reactor, limiting the overall lifespan of a reactor[1]. The Gaseous Lunar Oxygen from Regolith Electrolysis (GaLORE) project is focused on the development of a “cold-walled” or “Joule-heated” reactor design in which an internal heating source is used to selectively melt a pool of regolith between the electrodes of the reactor, leaving a shell of solidified regolith between the molten pool and the containment vessel of the reactor. This next generation reactor concept has been under development as molten oxide electrolysis (MOE) by MIT and Boston Metal for the production of iron from pure ores for terrestrial application [2]. The GaLORE project in engaged in early development of the technology for use with varying lunar regolith compositionsin the lunar environment. Thermal modelling of a proposed cold-walledreac-tor design were used as a scaffold to develop pa-rameters for a feasible reactor shape and size as well as target energy consumption[3]. The current development effort for the cold-walled reactor de-sign will be presented as a trade study of the most promising techniques for melting regolithwithin the constraints imposed by the lunar environment.Heater devices are designed to accommodate lim-ited electrical power availabilityon the moon, a wide range of regolith compositions that may be seen on the moon, limited metals available for re-placing consumed parts,and the low thermal con-ductivity of granular regolith in vacuum.Heater de-vices will be down-selectedbased on performance measurements within the above operationalcon-straints,and selected devices will be integrated into a reactor with electrodes to begin producing oxygen. [1]Sibille,L.,Sadoway, D.R.,Sirk, A., Tripathy,P.,Melendez, O., Standish, E., Dominguez, J. A., Stefanescu, D.M.,Curreri, P.A., Poizeau,S.,2009. “Recent Advancesin Scale-up Development of Molten Regolith Electrolysis for Oxygen Production in support of a Lunar Base.”AIAA 2009-659, 47th AIAA Aerospace Sciences Meeting, 5 -8 January 2009, Orlando, FL. [2] Boston Metal, https://www.boston-metal.com/moe-technology/#moe-process[3]Schreiner, S.S.,Sibille, L., Dominguez, J.A., Hoffman, J.A., 2016. "A parametric sizing model for Molten Regolith Electrolysis reactors to pro-duce oxygen on the Moon." Advances in Space Research 57.,7,1585-1603.

K D Grossman↗

NASA NTRS1975

Investigation of electroforming techniques, literature analysis report

A literature analysis is presented of reports, specifications, and documented experiences with the use of electroforming to produce copper and nickel structures for aerospace and other engineering applications. The literature period covered is from 1948 to 1974. Specific effort was made to correlate mechanical property data for the electrodeposited material with known electroforming solution compositions and operating conditions. From this survey, electrolytes are suggested for selection to electroform copper and nickel outer shells on regeneratively cooled thrust chamber liners, and other devices subject to thermal and pressure exposure, based on mechanical properties obtainable, performance under various thermal environments, and ease of process control for product reproducibility. Processes of potential value in obtaining sound bonds between electrodeposited copper and nickel and copper alloy substrates are also discussed.

Malone, G. A.↗

NASA NTRS1977

Stability analysis of a reinforced carbon carbon shell

This paper presents the development of a stability analysis for the nose cap of the NASA Space Shuttle Orbiter. Stability is evaluated by the differential stiffness analysis of the NASTRAN finite-element computer code, addressing those nonstandard characteristics in the nose cap such as nonuniform curvature, asymmetrical and nonuniform loads, support fixity, and various combinations of membrane and bending stresses. A full-sized nose cap, thinner than production, was statically tested and stability analyzed. The failing load level correlated to within 30%. The region and mode of buckling that occurred during test was accurately predicted by analysis. The criterion for predicting instability is based on the behavior of the nonlinear deflections. The deflections are nonlinear elastic in that the stresses are well within the elastic range of the material, but the geometry-load relationship produces nonlinear deflections. The load-deflection relationship is well defined by differential stiffness analysis up to the zero-slope portion of the curve, the point of neutral stability or where the shell 'snaps through' just prior to general instability.

Agan, W. E.↗

NASA NTRS1972

A computer program for the geometrically nonlinear static and dynamic analysis of arbitrarily loaded shells of revolution, theory and users manual

A digital computer program known as SATANS (static and transient analysis, nonlinear, shells) for the geometrically nonlinear static and dynamic response of arbitrarily loaded shells of revolution is presented. Instructions for the preparation of the input data cards and other information necessary for the operation of the program are described in detail and two sample problems are included. The governing partial differential equations are based upon Sanders' nonlinear thin shell theory for the conditions of small strains and moderately small rotations. The governing equations are reduced to uncoupled sets of four linear, second order, partial differential equations in the meridional and time coordinates by expanding the dependent variables in a Fourier sine or cosine series in the circumferential coordinate and treating the nonlinear modal coupling terms as pseudo loads. The derivatives with respect to the meridional coordinate are approximated by central finite differences, and the displacement accelerations are approximated by the implicit Houbolt backward difference scheme with a constant time interval. The boundaries of the shell may be closed, free, fixed, or elastically restrained. The program is coded in the FORTRAN 4 language and is dimensioned to allow a maximum of 10 arbitrary Fourier harmonics and a maximum product of the total number of meridional stations and the total number of Fourier harmonics of 200. The program requires 155,000 bytes of core storage.

Ball, R. E.↗

NASA NTRS2010

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

Dominguez, Jesus↗

NASA NTRS2010

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.↗

NASA NTRS2012

Joule-Heated Molten Regolith Electrolysis Reactor Concepts for Oxygen and Metals Production on the Moon and Mars

Sibille, Laurent↗

NASA NTRS2020

The Silicon Meta-shell X-ray Mirror Technology Development Roadmap for the Lynx Mission

This document presents a roadmap for advancing the silicon meta-shell optics (SMO). It describes an overall strategy and key technical elements to be developed to meet the four-fold Lynx requirements: (1) angular resolution, (2) effective area, (3) mass, and (4) production schedule and cost. It also describes the building and testing of an engineering unit whose successful completion will retire all risks, technical, logistical, schedule, and cost, associated with building and delivering a mirror assembly for the Lynx mission. All of this work, designed to advance this technology to TRL 6, will be completed by Preliminary Design Review (PDR) to ensure that the flight mirror assembly production process will be but a repetition of a set of well-defined and mature steps, leading to on-time and on-budget delivery of a mirror assembly for the Lynx mission.

Zhang, William W.↗

NASA NTRS1993

Plastic Foam Withstands Greater Temperatures And Pressures

Improved plastic foam suitable for use in foam-core laminated composite parts and in tooling for making fiber/matrix-composite parts. Stronger at high temperatures, more thermally and dimensionally stable, machinable, resistant to chemical degradation, and less expensive. Compatible with variety of matrix resins. Made of polyisocyanurate blown with carbon dioxide and has density of 12 to 15 pounds per cubic feet. Does not contibute to depletion of ozone from atmosphere. Improved foam used in cores of composite panels in such diverse products as aircraft, automobiles, railroad cars, boats, and sporting equipment like surfboards, skis, and skateboards. Also used in thermally stable flotation devices in submersible vehicles. Machined into mandrels upon which filaments wound to make shells.

Cranston, John A.↗

NASA NTRS2014

Coupled Fluid-Structure Interaction Analysis of Solid Rocket Motor with Flexible Inhibitors

Flexible inhibitors are generally used in solid rocket motors (SRMs) as a means to control the burning of propellant. Vortices generated by the flow of propellant around the flexible inhibitors have been identified as a driving source of instabilities that can lead to thrust oscillations in launch vehicles. Potential coupling between the SRM thrust oscillations and structural vibration modes is an important risk factor in launch vehicle design. As a means to predict and better understand these phenomena, a multidisciplinary simulation capability that couples the NASA production CFD code, Loci/CHEM, with CFDRC's structural finite element code, CoBi, has been developed. This capability is crucial to the development of NASA's new space launch system (SLS). This paper summarizes the efforts in applying the coupled software to demonstrate and investigate fluid-structure interaction (FSI) phenomena between pressure waves and flexible inhibitors inside reusable solid rocket motors (RSRMs). The features of the fluid and structural solvers are described in detail, and the coupling methodology and interfacial continuity requirements are then presented in a general Eulerian-Lagrangian framework. The simulations presented herein utilize production level CFD with hybrid RANS/LES turbulence modeling and grid resolution in excess of 80 million cells. The fluid domain in the SRM is discretized using a general mixed polyhedral unstructured mesh, while full 3D shell elements are utilized in the structural domain for the flexible inhibitors. Verifications against analytical solutions for a structural model under a steady uniform pressure condition and under dynamic modal analysis show excellent agreement in terms of displacement distribution and eigenmode frequencies. The preliminary coupled results indicate that due to acoustic coupling, the dynamics of one of the more flexible inhibitors shift from its first modal frequency to the first acoustic frequency of the solid rocket motor. This insight could have profound implications for SRM and flexible inhibitor designs for current and future launch vehicles including SLS.

Yang, H. Q.↗

NASA NTRS1993

Improved Real-Time Monitoring Using Multiple Expert Systems

Monitor/Analyzer of Real-Time Voyager Engineering Link (MARVEL) computer program implements combination of techniques of both conventional automation and artificial intelligence to improve monitoring of complicated engineering system. Designed to support ground-based operations of Voyager spacecraft, also adapted to other systems. Enables more-accurate monitoring and analysis of telemetry, enhances productivity of monitoring personnel, reduces required number of such personnel by performing routine monitoring tasks, and helps ensure consistency in face of turnover of personnel. Programmed in C language and includes commercial expert-system software shell also written in C.

Schwuttke, Ursula M.↗

NASA NTRS2012

A Novel Technique for Running the NASA Legacy Code LAPIN Synchronously With Simulations Developed Using Simulink

This report presents a method for running a dynamic legacy inlet simulation in concert with another dynamic simulation that uses a graphical interface. The legacy code, NASA's LArge Perturbation INlet (LAPIN) model, was coded using the FORTRAN 77 (The Portland Group, Lake Oswego, OR) programming language to run in a command shell similar to other applications that used the Microsoft Disk Operating System (MS-DOS) (Microsoft Corporation, Redmond, WA). Simulink (MathWorks, Natick, MA) is a dynamic simulation that runs on a modern graphical operating system. The product of this work has both simulations, LAPIN and Simulink, running synchronously on the same computer with periodic data exchanges. Implementing the method described in this paper avoided extensive changes to the legacy code and preserved its basic operating procedure. This paper presents a novel method that promotes inter-task data communication between the synchronously running processes.

Vrnak, Daniel R.↗

NASA NTRS1991

Rule groupings in expert systems using nearest neighbour decision rules, and convex hulls

Expert System shells are lacking in many areas of software engineering. Large rule based systems are not semantically comprehensible, difficult to debug, and impossible to modify or validate. Partitioning a set of rules found in CLIPS (C Language Integrated Production System) into groups of rules which reflect the underlying semantic subdomains of the problem, will address adequately the concerns stated above. Techniques are introduced to structure a CLIPS rule base into groups of rules that inherently have common semantic information. The concepts involved are imported from the field of A.I., Pattern Recognition, and Statistical Inference. Techniques focus on the areas of feature selection, classification, and a criteria of how 'good' the classification technique is, based on Bayesian Decision Theory. A variety of distance metrics are discussed for measuring the 'closeness' of CLIPS rules and various Nearest Neighbor classification algorithms are described based on the above metric.

Anastasiadis, Stergios↗

NASA NTRS1986

Quantum mechanical signature in exclusive coherent pion production

We calculate the coherent production of pions from subthreshold to relativistic energies in heavy-ion collisions using a quantum, microscopic, many-body model. For the first time, in this approach, we use harmonic oscillator wave functions to describe shell-model information. The theoretical quantum mechanical results obtained for the pion spectra represent an important improvement over our previous microscopic, many-body calculations.

NASA Discipline Radiation Health↗

NASA NTRS2004

Acquisition of a Gas Chromatograph/Mass Spectrometer System for Laboratory Study of Prebiotic Organic Geochemical Processes on the Early Earth, Mars, and Meteorites

This was a major equipment grant that provided funds ($72K) for purchase of a benchtop gas chromatograph-mass spectrometer (GC-MS) for use in experimental studies of prebiotic organic compounds. An Agilent model 689015973 GC-MS was purchased and installed in the PI's lab in August of 2003. The instrument is now being used for a variety of research projects. The primary use of the instrument is to analyze and quantify organic products of laboratory experiments conducted by the PI. One example is shown, which shows organic products (predominantly n-alkanes) formed during Fischer-Tropsch-type abiotic synthesis under hydrothermal conditions. The analytical capabilities of the GC- MS allowed identification of the numerous organic products of this as well as other laboratory experiments. A key use of the instrument in this research is that the mass spectrometer capabilities allow use of isotopically labeled reactants to trace the progress of reactions and evaluate background contaminants. collaborative projects with other scientists involved in exobiology & astrobiology research (e.g., Mitch Schulte, NASA Ames; Katrina Edwards, Woods Hole Oceanographic Institution). For instance, an analysis of membrane lipids of an lithoautotrophic iron-oxidizing bacteria being grown on basalt as a source of metabolic energy, a project where the instrument is being used to evaluate possible biomarker compounds from these organisms is shown. These iron oxidizers are thought to be similar to those living within the ocean crust, and are being investigated as possible analog organisms to those on the early Earth or crust of Mars. The instrument has also been used by an outside investigator (graduate student Brandon Canfeld, Arizona State University) for identification and isotopic characterization of experimental products of abiotic organic synthesis experiments he is conducting with Dr. John Holloway. analysis of quality control samples for other NASA-funded projects. For instance, an analysis of residual hydrocarbon contaminants on the internal surface of the shell of an atmospheric sounding rocket is shown. This analysis was used to help determine the source of the contaminating compounds. In the future, the instrument will continue to be used for quality control analysis in clean rooms and instrument construction facilities within the Laboratory for Atmospheric and Space Physics, where the GC-MS is housed.

McCollom, Thomas↗

NASA NTRS2012

Next Generation Astronomical X-ray Optics: High Angular Resolution, Light Weight, and Low Production Cost

X-ray astronomy depends on the availability of telescopes with high resolution and large photon collecting areas. Since x-ray observation can only be carried out above the atmosphere, these telescopes must be necessarily lightweight. Compounding the lightweight requirement is that an x-ray telescope consists of many nested concentric shells, which further require that x-ray mirrors must also be geometrically thin to achieve high packing efficiency. This double lightweight and geometrically thin requirement poses significant technical challenges in fabricating the mirrors and in integrating them into mirror assemblies. This paper reports on the approach, strategy and status of our x-ray optics development program whose objective is to meet these technical challenges at modest cost to enable future x-ray missions, including small Explorer missions in the near term, probe class missions in the medium term, and large flagship missions in the long term.

Zhang. W. W.↗

NASA NTRS1972

The theoretical output of a ring core fluxgate sensor.

Demonstration that the output from a ring core sensor is directly proportional to the first time derivative of the product of dynamic permeability and magnetic intensity perturbation within the core caused by an external, uniform magnetic field. (Dynamic permeability is defined to be the slope of the hysteresis loop at a given point in time). Assuming that ellipsoidal shells can approximate the core, the demagnetization factor can be 'estimated' in the first order to be proportional to the first power of the quantity tape thickness (or number of wraps) divided by the core diameter. The constant of proportionality is determined from laboratory data. When an additional scale adjustment is applied to the resulting sensor output formula, the computed output tracks laboratory data for a range of sensor geometries.

Burger, J. R.↗

NASA NTRS1994

Oil Spill Cleanup

Petroleum Remediation Product (PRP) is a new way of cleaning up oil spills. It consists of thousands of microcapsules, tiny balls of beeswax with hollow centers, containing live microorganisms and nutrients to sustain them. As oil flows through the microcapsule's shell, it is consumed and digested by the microorganisms. Pressure buildup causes the PRP to explode and the enzymes, carbon dioxide and water are released into the BioBoom used in conjunction with PRP, preventing contaminated water from spreading. The system incorporates technology originally developed at the Jet Propulsion Laboratory and Marshall Space Flight Center.

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