Development of core cladding fabrication techniques for Phase I fission propulsion systems
Phase I fission propulsion systems focus on safety, timely development, and affordability. Prototype and flight units can be tested at full thrust, using resistance heaters to closely simulate heat from a fission reaction. In Phase I ground testing, one goal is to establish a reliable and affordable manufacturing technique for fabricating a flight-like core. A refractory metal (Mo) has been suggested for the core substrate, primarily due to the existence of a significant database for Mo/LJ02 fuel. The core can be fabricated by bundling Mo tubes with a bonding system that meets preliminary test goals. These criteria include materials compatibility, ability to maintain thermal and structural integrity during 10,000 hours of operation, and fabrication with existing facilities. This paper describes an effort to investigate several fabrication techniques in a cost-effective manner. First, inexpensive materials were tested at low temperatures to determine the relative effectiveness of such techniques as welding, brazing, plating, and vacuum plasma spraying (VPSing). Promising techniques were chosen for further evaluation, including thermal and structural studies, using ceramic tubing at intermediate temperatures. The most desirable technique will be tested on actual Mo tubing at anticipated operating temperatures. This work is being performed by the National Aeronautics & Space Administration (NASA) at George C. Marshall Space Flight Center (MSFC), Los Alamos National Laboratory (LANL), and Advanced Methods & Materials (AMM), Inc.
First Generation Least Expensive Approach to Fission (FiGLEAF) Testing Results
Successful development of space fission systems will require an extensive program of affordable and realistic testing. In addition to tests related to design/development of the fission system, realistic testing of the actual flight unit must also be performed. Testing can be divided into two categories, non-nuclear tests and nuclear tests. Full power nuclear tests of space fission systems are expensive, time consuming, and of limited use, even in the best of programmatic environments. If the system is designed to operate within established radiation damage and fuel burn up limits while simultaneously being designed to allow close simulation of heat from fission using resistance heaters, high confidence in fission system performance and lifetime can be attained through a series of non-nuclear tests. Non-nuclear tests are affordable and timely, and the cause of component and system failures can be quickly and accurately identified. MSFC is leading a Safe Affordable Fission Engine (SAFE) test series whose ultimate goal is the demonstration of a 300 kW flight configuration system using non-nuclear testing. This test series is carried out in collaboration with other NASA centers, other government agencies, industry, and universities. The paper describes the SAFE test series, which includes test article descriptions, test results and conclusions, and future test plans.
Operating Characteristics of a 15-cm dia. Ion Engine for Small Planetary Spacecraft
A 15-cm diameter, scaled-down version of the NASA light-weight 30-cm ion engine has been developed for potential application to very small planetary spacecraft. Integration of the 15-cm ion source into 4x15-cm segmented engine configuration results in a 30-cm equivalent engine which can be throttled over a 7-to-1 input power variation with a constant beam current in each of the four segments. Throttling the segmented engine by turning off individual segments can result in a significant decrease in the required service life (and qualification requirements) of the ion source components.