Currently, no single material satisfies all the design requirements for plasma facing components in magnetic fusion devices. therefore complex designs have been proposed and tested, but operation of the devices is still limited. innovative techniques are planned in this project to fabricate… More

196 Beryllium and Tungsten Brush Armor for Plasma Facing Components--Plasma Processes, Inc., 4914 D Moores Mill Road, Huntsville, AL 35811-1558; (205) 851-7653 Dr. Timothy McKechnie, Principal Investigator Ms. Cheri McKechnie, Business Official DOE Grant No. DE-FG02-97ER82458 Amount: … More

40903 November 18, 1996 Plasma Processes, Inc. Due to its high melting point, good thermal conductivity, low sputtering rate, and disruption resistance, tungsten armor is being considered for magnetic fusion energy devices such as the International… More

196 Beryllium and Tungsten Brush Armor for Plasma Facing Components--Plasma Processes, Inc., 4914 D Moores Mill Road, Huntsville, AL 35811-1558; (205) 851-7653 Dr. Timothy McKechnie, Principal Investigator Ms. Cheri McKechnie, Business Official DOE Grant No. DE-FG02-97ER82458 Amount: … More

50304-98-I High Temperature Oxidation Resistant Alumina Coatings for Advanced Energy and Processing Systems--Plasma Processes, Inc., 4914 D Moores Mill Road, Huntsville, AL 35811-1558; (205) 851-7653 Mr. Timothy McKechnie, Principal Investigator Mr. Timothy McKechnie, Business Official DOE Grant… More

50467-98-I Beryllium Armored Aluminum Alloy Plasma Facing Components--Plasma Processes, Inc., 4914 D Moores Mill Road, Huntsville, AL 35811-1558; (205) 851-7653 Mr. Timothy Mckechnie, Principal Investigator Mr. Timothy Mckechnie, Business Official DOE Grant No. DE-FG02-98ER82644 Amount: … More

Not Available We propose to construct a novel random phase mask that takes advantage of new gray-scale lithography to improve the performance of high throughput volumetric memories. The focus of the effort will be to produce a phase mask prototype during Phase I that can be integrated onto a… More

With the completion of the International Space Station, access to microgravity for materials science experiments will increase significantly. Versatile sample containment fabrication techniques are needed to meet the science requirements of NASA's principle investigators. New quenching requirements… More

With the completion of the International Space Station, access to microgravity for materials science experiments will increase significantly. Versatile sample containment fabrication techniques are needed to meet the science requirements of NASA's principle investigators. New quenching requirements… More

"To meet DoD and IHPRPT requirements, the cost of rocket enginesneeds to be reduced while increasing performance. Rhenium isbeing used for nozzles and hot gas valve components because ofits high melting temperature and chemicalstability. However, the difficulty of forming rhenium and otherrefractory… More

70508 To reduce the cost of burning plasma experiments, conducted for fusion energy research, refractory metals are required as plasma facing components to increase high heat flux limitations. For refractory metals such as tungsten (W) to be used in these applications, improvements to both… More

70732 Helium has been found to be an attractive coolant for fusion power plants based on its safety advantages and compatibility with structural materials at high temperature. However, gas coolants in general tend to provide modest heat transfer performance due to their inherently low heat… More

"Beryllium has been for used for generations in the aerospace structures and other applications due to its lightweight, high stiffness, low thermal expansion and high thermal conductivity. Despite its usefulness, beryllium is not an ideal material as it isexpensive, too brittle to work and poses a… More

High temperature, corrosion resistant cartridge materials are needed for microgravity processing experiments. Tungsten and molybdenum have high melting temperatures and in general possess the required chemical inertness. To improve the mechanical properties of these materials, alloy additions such… More

High temperature, corrosion resistant cartridge materials are needed for microgravity processing experiments. Tungsten and molybdenum have high melting temperatures and in general possess the required chemical inertness. To improve the mechanical properties of these materials, alloy additions such… More

Innovative technologies are needed to increase performance and reduce life-cycle cost of rocket engine components. Fabrication of lightweight engine components such as injector faceplates and nozzle ramps offer great potential for increasing thrust to weight ratios and reducing costs. Current… More

70508B02-II To reduce the cost of burning-plasma experiments conducted for fusion energy research, refractory metals are required to increase high heat flux limitations for plasma facing component applications. For refractory metals such as tungsten (W) to be used in fusion applications,… More

Two critical aspects for microgravity materials experiments are to ensure the safety of the International Space Station (ISS) crew/hardware and to maximize the level of obtainable science. Several of the materials processing experiments for the Quench Module Insert (QMI), one of the first Experiment… More

Experiment Modules (EM) such as the Quench Module Insert (QMI) must be comprised of robust components to minimize the need for recalibration and refurbishment/replacement on the International Space Station. A critical aspect for proper operation of the QMI is thermal performance monitoring by… More

70848T02-II Fuel oil is an important part of the energy supply mix for commercial and large residential buildings, but the development of low emission, high performance burners has received little attention. Recent advances in recirculating burner development with low pressure air atomization… More

70508B02-II To reduce the cost of burning-plasma experiments conducted for fusion energy research, refractory metals are required to increase high heat flux limitations for plasma facing component applications. For refractory metals such as tungsten (W) to be used in fusion applications,… More

Non-conventional technologies are needed to revolutionize space propulsion. Development of materials with improved properties is essential to increase performance and reduce cost. Advancements are needed for components in high powered electrical, beamed energy, and nuclear propulsion systems.… More

Missile defense urgently needs a new generation of boosters with increased reliability and performance. Many missile defense systems currently being tested use older modified missiles that have malfunctioned during testing. As a result, critical testinghas been delayed. Boost phase, intercept… More

Experiment Modules (EM) such as the Quench Module Insert (QMI) must be comprised of robust components to minimize the need for recalibration and refurbishment/replacement on the International Space Station. A critical aspect for proper operation of the QMI is thermal performance monitoring by… More

Non-conventional technologies are needed to revolutionize space propulsion. Development of materials with improved properties is essential to increase performance and reduce cost. Advancements are needed for components in solid and hybrid rocket, high powered electrical, beamed energy, and nuclear… More

Low cost, boost phase nozzles are needed for missile defense systems. Boost phase intercept missiles require high thrust motors that operate at very high pressures and temperatures. The nozzles must survive high thermal strains with minimal erosion to maintain performance. Current R&D focuses on… More

Crucibles comprised of an internal ceramic liner in direct contact with a metal reinforcement are desired to maximize heat transfer between the sample and the furnace for materials processing experiments in microgravity. Previous work by Plasma Processes Inc. has demonstrated forming techniques to… More

In order to safely explore space, humans must be protected from radiation. There are 2 predominant sources of extraterrestrial ionizing radiation, namely, Galactic Cosmic Rays (GCR) consisting primarily of nuclei of atoms (up to Fe) and Solar Energetic Particles (SEP), which includes mainly… More

75376-Reactor studies have identified liquid lithium walls as a promising solution to magnetic fusion energy (MFE) first-wall problems. However, the implementation of a flowing liquid lithium first wall in a fusion experiment is complicated by magnetohydrodynamic (MHD) effects produced in… More

For materials processing experiments in microgravity, crucibles comprised of an internal ceramic liner in direct contact with a metal reinforcement are desired to maximize heat transfer. Previous work has demonstrated the advantages of reinforced crucibles for producing samples with enhanced… More

Radiation shielding simulations showed that epoxy loaded with 10-70% polyethylene would be an excellent shielding material against GCRs and SEPs. Milling produced an elemental boron coating on the polyethylene particles suitable for protecting against low energy neutrons. For up to 30 volume… More

75376B Reactor studies have identified liquid lithium walls as a promising solution to magnetic fusion energy first wall problems. For near-term applications, such as the Lithium Tokamak eXperiment (LTX), a thin-film approach has been pursued; however, thin lithium films can become saturated with… More

Revolutionizing the space propulsion industry through innovative, relatively low-cost, manufacturing techniques is extremely needed. Specifically, advancements are needed for components in new high-powered electrical, beamed energy, and nuclear propulsion systems. Innovative processes for… More

Advanced missile defense interceptors will provide our nation with the capability of defeating threats to our homeland and our deployed troops. However, the fielding of these advanced interceptors is strongly dependent upon technologies that enable production of interceptor boost nozzles capable of… More

Low cost, tactical missiles such as the U.S. Army's PAM (Precision Attack Missile) will provide our nation with the capability of defeating threats to our deployed troops. However, improvements are desired in an effort to meet future missile requirements. One particular enhancement is the… More

Tools for extracting resources from the moon are needed to support future space missions. Of particular interest is the production of raw materials for in-space fabrication. In addition, oxygen and water for habitat and propulsion purposes is needed. The only practical source for these materials… More

Helium-cooled, refractory-metal heat sinks are being considered for the divertor sections of several fusion energy reactors. Research results have shown considerable promise for the use of jet-impingement-type helium-cooling techniques in high-heat-flux applications. However, because of the small… More

Molybdenum has been identified as a promising material for many high temperature NASA applications due to its high melting temperature, resistance to liquid metals, resistance to hot hydrogen, high thermal conductivity, and relatively low density. However, molybdenum's ductile to brittle transition… More

Advanced, high-temperature Reaction Jet Control (RJC) systems provide agility, maneuverability and end-game lethality to missiles and precision guided munitions. The biggest technical challenge of the RJC program is developing low-cost, lightweight valves to withstand the extreme temperature… More

Advanced bipropellant engines are needed for ARES/ORION vehicle maneuvering and future deep space science missions. Currently, an iridium-lined rhenium combustion chamber is the state-of-the-art for in-space propulsion applications. An example of an in-space engine that incorporates an… More

Tools for extracting resources from the moon are needed to support future space missions. Of particular interest is the production of gases and metals for life support, propulsion, and in-space fabrication. The only practical source for these materials is the decomposition of lunar regolith.… More

Helium-cooled, refractory metal heat sinks are being considered for the divertor sections of several fusion energy reactors. One type of helium cooling, jet impingement, has shown promise for high heat flux applications. However, because of the small size of the units (1.5-2 cm), a large number of… More

The Network Centric Airborne Defense Element (NCADE) is an affordable boost- and ascent- phase ballistic missile interceptor system. NCADE has the same form, fit and interface as the Advanced Medium Range Air-to-Air Missile (AMRAAMT). The boost- and ascent-phase capability of NCADE is enabled by… More

Missile defense interceptors will provide our nation with the capability of defeating threats to our homeland and our deployed troops. However, the fielding of these advanced interceptors is strongly dependent upon technologies that enable production of high performance, low cost interceptor… More

The Pratt and Whitney Rocketdyne (PWR) J-2X engine will power the upper stage of the Ares I and the earth departure stage (EDS) of the Ares V, which will enable manned travels to the Moon and eventually Mars. Building on Apollo heritage, the J-2X is a derivative of the J 2 engine. One unique… More

Reaction Jet Control (RJC) systems will provide agility, maneuverability and end-game lethality to missiles and precision guided munitions. Demonstration of this technology is an important milestone in the development of next generation multi role missiles, such as the Joint Dual Role Air Dominance… More

Tungsten and its alloys are candidates for plasma-facing-component heat sinks and armor used in fusion energy systems, due to their low sputtering rate, high melting point, high thermal conductivity, high strength at elevated temperatures, and low tritium inventory. However, tungsten¿s inherent… More

A novel lightweight thrust chamber has been developed in support of axial propulsion, gas generators and divert and attitude control systems for missile defense interceptors. Characterization of metal lined carbon composites during Phase 2 will increase the technology readiness required for… More

Fielding of advanced missile defense interceptors is strongly dependent upon innovative concepts and technologies that can be applied across the Ballistic Missile Defense System to stay ahead of the threat, improve system capabilities and effectiveness, and lower life cycle costs. Tantalum carbide… More

Radiation-cooled, bipropellant thrusters are being considered for the Ascent Module main engine of the Altair Lunar Lander. Currently, iridium-lined rhenium combustion chambers are the state-of-the-art for radiatively cooled thrusters. To increase the performance of radiation-cooled engines,… More

The Launch Abort System (LAS) for the Orion Crew Exploration Vehicle (CEV) will provide a safe escape for the crew in the event of an emergency during launch. A key component of the LAS is its Attitude Control Motor (ACM). Recent testing of the ACM valve assembly has resulted in failure during… More

The ARES J-2X requires a large nozzle extension. Currently, a metallic nozzle extension is being considered with carbon-carbon composite as a backup. In Phase 1, Plasma Processes Inc. (PPI), with the support from subcontractor ATK Launch Systems, fabricated, coated and test fired Haynes 230 and… More

A tailorable structural composite that will provide protection from the lunar radiation environment, including GCR and albedo neutrons will be developed. This composite will have increased structural strength combined with more efficient shielding of GCR and albedo neutrons when compared to… More

Processing of lunar regolith into oxygen for habitat and propulsion is needed to support future space missions. Direct electrochemical reduction of molten regolith is most attractive method of processing because no additional chemical reagents are needed. The electrochemical processing of molten… More

The deleterious effects of lunar dust, typically less than 50 ýým in diameter, have to be addressed prior to establishing a human base and long duration human presence on the surface of the moon. These effects include abrasion of seals, gaskets, motors, actuators, gimbals, bearings, blocking… More

Tungsten¿s inherent chemical inertness and high melting temperature make it an ideal heat sink and armor material for fusion applications. However, tungsten¿s intrinsic low temperature brittleness makes it difficult to fabricate using conventional processing techniques. Recently, advanced… More

The key to higher efficiencies and lower emissions in next generation power plants, such as Integrated Gasification Combined Cycle (IGCC) systems, is an increase in the firing temperatures that are now limited by the turbines materials. In this project, higher-temperature thermal protection… More

Hypersonic missile defense systems are being designed to reach global threats. During flight, external surfaces are predicted to reach temperatures in excess of 2200C. As a result, innovative, high performance thermal protection systems (TPS) are of great demand. Among ultra-high temperature… More

Radiation-cooled, bipropellant thrusters are being considered for the Ascent Module main engine of the Altair Lunar Lander. Currently, iridium-lined rhenium combustion chambers are the state-of-the-art for radiatively cooled thrusters. To increase the performance of radiation-cooled engines,… More

Small and micro-spacecrafts require the efficient, micro-propulsion systems. Chemical micro-propulsion is best suited for use as primary thrust, orbital insertion and attitude control because of its high energy density. When grouped into arrays for larger thrust applications, micro-propulsion… More

Direct electrochemical reduction of molten regolith is the most attractive method of oxygen production on the lunar surface, because no additional chemical reagents are needed. The process is proven on a laboratory scale, but the cathode-anode system and melt containers need to be improved for… More

Future high maneuverability Divert Altitude and Control Systems (DACS) require improved performance and reduced environmental impacts, while maximizing kill vehicle divert capabilities and reducing weight within restricted geometries. Advanced "green" monopropellants promise significant improvements… More

The performance liquid propellant engines can be significantly improved by increasing both combustion temperature and pressure and reducing engine weight. State of the art Bi-propellant engines are metallic; the highest temperature combustion chambers are made of iridium/rhenium metals. Utilizing… More

The deleterious effects of lunar dust, typically less than 50

As NASA prepares for future exploration activities on the Moon, there is a growing need to develop higher fidelity lunar soil simulants that can accurately reproduce the properties and behavior of lunar soil. Simulants are employed on earth to verify the performance of equipment, mechanisms,… More

The US Navy is pursuing the development of an electromagnetic rail gun (EMRG) for long range naval surface fire support. Such guns have been built and operated successfully on a test basis, however several obstacles prevent them from usage in the field. One specific obstacle is the development of… More

Abstract Ion cyclotron range of frequency (ICRF) heating is expected to be an important auxiliary heating source for ITER and future fusion reactors, where high Z metallic plasma facing components (PFCs) will be used. The compatibility of high Z PFCs with high power ICRF heating is of considerable… More

Radiation-cooled, bipropellant thrust chambers are being considered for the ascent/descent engines and reaction control systems (RCS) for future NASA missions such as Mars Sample Return. Currently, iridium-lined rhenium combustion chambers are the state-of-the-art for in-space engines. NASA's… More

Non-toxic monopropellants have been developed that provide better performance than toxic hydrazine. Formulations based on hydroxylammonium nitrate (HAN) have superior performance as compared to hydrazine with Isp (261 seconds, 12% greater), higher density and volumetric impulse, lower melting point,… More

As NASA considers manned and/or unmanned return missions to the Moon and beyond, it is imperative that high fidelity lunar soil simulants be developed in order to accurately evaluate the life span and efficiency of any equipment exposed to the lunar surface. One of the significant limitations of… More

Abstract Ion cyclotron range of frequency (ICRF) power is anticipated to be a primary auxiliary heating source in next step tokamak experiments like ITER. From a technological perspective, electrical breakdown is a significant challenge for ICRF utilization in present experiments and will become… More

Rhenium is the current material of choice for several critical hot gas path components of Divert and Attitude Control Systems (DACS) due to its erosion resistance, high-temperature strength and compatibility with propellant products. However, disadvantages of Re include high cost and high density.… More

Rhenium is the current material of choice for several critical valve components in a solid divert and attitude control system (DACS) due to its erosion resistance, high-temperature strength, and compatibility with propellant exhaust products. However, bulk rhenium is disadvantaged by being… More

A novel lightweight thrust chamber has been developed in support of axial propulsion, gas generators and divert and attitude control systems for missile defense interceptors. Characterization of metal lined carbon composites during Phase 2 will increase the technology readiness required for… More

Fielding of advanced missile defense interceptors is strongly dependent upon innovative concepts and technologies that can be applied across the Ballistic Missile Defense System to stay ahead of the threat, improve system capabilities and effectiveness, and lower life cycle costs. Tantalum carbide… More

The US Navy is pursuing the development of an electromagnetic rail gun (EMRG), which promises to extend naval fire support and increase ship safety. Such guns have been built and operated successfully, however several obstacles prevent them from widespread usage in the field. One specific obstacle… More

Radiation-cooled, bipropellant thrust chambers are being considered for the ascent/descent engines and reaction control systems for NASA missions such as Mars Sample Return and Orion MPCV. Currently, iridium-lined rhenium combustion chambers are the state-of-the-art for in-space engines.… More

Non-toxic monopropellants have been developed that provide better performance than toxic hydrazine. Formulations based on hydroxylammonium nitrate (HAN) have superior performance as compared to hydrazine with Isp (261 seconds, 12% greater), higher density and volumetric impulse (60% greater… More

Rhenium is the current material of choice for Divert and Attitude Control Systems (DACS) components of due to its erosion resistance, high-temperature strength and compatibility with propellant products. However, disadvantages of Re include high cost and high density. Alternatives to Re such as… More