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The Early Flight Fission-Test Facilities (EFF-TF) team at NASA Marshall Space Flight Center (MSFC) has been tasked by the Naval Reactors Prime Contract Team (NRPCT) to provide a cost and delivery rough order of magnitude estimate for a refractory metal-based lithium (Li) flow circuit. The design is based on the stainless steel Li flow circuit that is currently being assembled for an NRPCT task underway at the EFF-TF. While geometrically the flow circuit is not representative of a final flight prototype, knowledge has been gained to quantify (time and cost) the materials, manufacturing, fabrication, assembly, and operations to produce a testable configuration. This Technical Memorandum (TM) also identifies the following key issues that need to be addressed by the fabrication process: Alloy selection and forming, cost and availability, welding, bending, machining, assembly, and instrumentation. Several candidate materials were identified by NRPCT including molybdenum (Mo) alloy (Mo-47.5 %Re), tantalum (Ta) alloys (T-111, ASTAR-811C), and niobium (Nb) alloy (Nb-1 %Zr). This TM is focused only on the Mo and Ta alloys, since they are of higher concern to the ongoing effort. The initial estimate to complete a Mo-47%Re system ready for testing is =$9,000k over a period of 30 mo. The initial estimate to complete a T-111 or ASTAR-811C system ready for testing is =$12,000k over a period of 36 mo.

The Early Flight Fission-Test Facilities (EFF-TF) team was tasked by Naval Reactors Prime Contract Team (NRPCT) to design, fabricate, and test an actively pumped lithium (Li) flow circuit. This Li circuit takes advantage of work in progress at the EFF TF on a stainless steel sodium/potassium (NaK) circuit. The effort involved modifying the original stainless steel NaK circuit such that it could be operated with Li in place of NaK. This new design considered freeze/thaw issues and required the addition of an expansion tank and expansion/extrusion volumes in the circuit plumbing. Instrumentation has been specified for Li and circuit heaters have been placed throughout the design to ensure adequate operational temperatures and no uncontrolled freezing of the Li. All major components have been designed and fabricated prior to circuit redesign for Li and were not modified. Basic circuit components include: reactor segment, Li to gas heat exchanger, electromagnetic liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and trace heaters. The reactor segment, based on a Los Alamos National Laboratory 100-kW design study with 120 fuel pins, is the only prototypic component in the circuit. However, due to earlier funding constraints, a 37-pin partial-array of the core, including the central three rings of fuel pins (pin and flow path dimensions are the same as those in the full design), was selected for fabrication and test. This Technical Publication summarizes the design and integration of the pumped liquid metal Li flow circuit as of May 1, 2005. This supplement contains drawings, analysis, and calculations

Heat pipe life tests described in the literature have seldom been conducted on a systematic basis. Typically one or more heat pipes are built and tested for an extended period at a single temperature with simple condenser loading. This paper describes an approach to generate carefully controlled data that can conclusively establish heat pipe operating life with material-fluid combinations capable of extended operation. Approximately 10 years of operational life might be compressed into 3 years of laboratory testing through a combination of increased temperature and mass fluence. Two specific test series have been identified and include: investigation of long term corrosion rates based on the guidelines contained in ASTM G-68-80 (using 7 heat pipes); and investigation of corrosion trends in a cross correlation sequence at various temperatures and mass fluences based on a central composite test design (using 9 heat pipes). The heat pipes selected for demonstration purposes are fabricated from a Mo-44.5%Re alloy with a length of 0.3 meters and a diameter of 1.59 cm(to conserve material) with a condenser to evaporator length ratio of approximately 3. The wick is a crescent annular design formed from 400-mesh Mo-Re alloy material hot isostatically pressed to produce a final wick core of 20 microns or less.

The focus of this work was to establish an approach to generate carefully controlled data that can conclusively establish heat pipe operating life with material-fluid combinations capable of extended operation. To accomplish this goal acceleration is required to compress 10 years of operational life into 3 years of laboratory testing through a combination of increased temperature and mass fluence. Specific test series have been identi3ed, based on American Society for Testing and Materials (ASTM) specifications, to investigate long term corrosion rates. The refractory metal selected for demonstration purposes is a Molybdenum-44.5%Rhenium alloy formed by powder metallurgy. The heat pipe makes use of an annular crescent wick design formed by hot isostatic pressing of Molybdenum-Rhenium wire mesh. The heat pipes are filled using vacuum distillation and purity sampling is considered. Testing of these units is round-the-clock with 6-month destructive and non-destructive inspection intervals to identify the onset and level of corrosion. Non-contact techniques are employed for providing power to the evaporator (radio frequency induction heating at I to 5 kW per unit) and calorimetry at the condenser (static gas gap coupled water cooled calorimeter). The planned operating temperature range would extend from 1123 to 1323 K. Accomplishments prior to project cancellation included successful demonstration of the heat pipe wick fabrication technique, establishment of all engineering designs, baselined operational test requirements and procurement/assembly of supporting test hardware systems.

The High performance Antiproton Trap (HiPAT) research project was initiated by the Marshall Space Flight Center's propulsion Research Center to examining the fundamental behavior of low energy antiprotons. Stored antiproton would ultimately be used for experimental demonstration of basic propulsive concepts. Matter-antimatter annihilation produces approximately 10(exp 8) MJ/g nearly 10 orders of magnitude more energy per unit mass than chemical based combustion, hence NASA's interest. To achieve containment, HiPAT utilizes a type of electromagnetic bottle know as a Penning trap positioned within an ultrahigh vacuum test section. Recently, the HiPAT hardware configuration has been enhanced to facilitate the capture of multiple normal matter ion burst. This endeavor is often referred to as "stacking" and used to increasing the number of captured particles. A prior normal matter experimental effort, successfully demonstrated the effectiveness of single burst capture. The stacking process is accomplished by manipulating the electric field generated by the confinement electrodes i.e. adjusting the well potential depth. These potential well values are initially configured to maximize the quantity of captured ions per burst; shallow wells with a depth of 100 volt or less (referenced to the incoming ion beam energy) are typically selected. Once captured, a cooling interval is required to reduce the energy of trapped particles below the lower extent of the "trap door" (or leading electrode) ion emitting potential. This is necessary such that a new burst of hot ions can be introduced while preventing those already inside from escaping. The cooling time is driven by a combination of mechanisms such as synchrotron radiation, background gas scattering, and resistive damping in a time scale on the order of minutes. A potential for reducing this hold period is to actively manipulate the electric field shape, using the power supply control system, to produce a deeper potential well. The trapped ions ride down the morphing well to a lower potential energy, leaving margin to once again cycle the "trap door" capturing a new burst while limiting the number of escaping ions. By adjusting the magnitude and timing of the potential well shaping, subsequent shots from the ion beam can be captured on a time scale shorter then that dictated by the standard inject, capture and cool technique. Currently, experimental tests are under way examining the functionally of this system for stacking multiple ions bursts within the HiPAT system.

A heat pipe cooled reactor is one of several candidate reactor cores being considered for advanced space power and propulsion systems to support future space exploration applications. Long life heat pipe modules, with designs verified through a combination of theoretical analysis and experimental lifetime evaluations, would be necessary to establish the viability of any of these candidates, including the heat pipe reactor option. A hardware-based program was initiated to establish the infrastructure necessary to build heat pipe modules. This effort, initiated by Los Alamos National Laboratory and referred to as the Safe Affordable Fission Engine (SAFE) project, set out to fabricate and perform non-nuclear testing on a modular heat pipe reactor prototype that can provide 100 kilowatt from the core to an energy conversion system at 700 C. Prototypic heat pipe hardware was designed, fabricated, filled, closed-out and acceptance tested.

The High Performance Antiproton Trap (HiPAT), a system designed to hold up to l0(exp 12) charge particles with a storage half-life of approximately 18 days, is a tool to support basic antimatter research. NASA's interest stems from the energy density represented by the annihilation of matter with antimatter, 10(exp 2)MJ/g. The HiPAT is configured with a Penning-Malmberg style electromagnetic confinement region with field strengths up to 4 Tesla, and 20kV. To date a series of normal matter experiments, using positive and negative ions, have been performed evaluating the designs performance prior to operations with antiprotons. The primary methods of detecting and monitoring stored normal matter ions and antiprotons within the trap includes a destructive extraction technique that makes use of a micro channel plate (MCP) device and a non-destractive radio frequency scheme tuned to key particle frequencies. However, an independent means of detecting stored antiprotons is possible by making use of the actual annihilation products as a unique indicator. The immediate yield of the annihilation event includes photons and pie mesons, emanating spherically from the point of annihilation. To "count" these events, a hardware system of scintillators, discriminators, coincident meters and multi channel scalars (MCS) have been configured to surround much of the HiPAT. Signal coincidence with voting logic is an essential part of this system, necessary to weed out the single cosmic ray events from the multi-particle annihilation shower. This system can be operated in a variety of modes accommodating various conditions. The first is a low-speed sampling interval that monitors the background loss or "evaporation" rate of antiprotons held in the trap during long storage periods; provides an independent method of validating particle lifetimes. The second is a high-speed sample rate accumulating information on a microseconds time-scale; useful when trapped antiparticles are extracted against a target, providing an indication of quantity. This paper details the layout of this system, setup of the hardware components around HiPAT, and applicable checkouts using normal matter radioactive sources.

The significant energy density of matter-antimatter annihilation is attractive to the designers of future space propulsion systems, with the potential to offer a highly compact source of power. Many propulsion concepts exist that could take advantage of matter-antimatter reactions, and current antiproton production rates are sufficient to support basic proof-of-principle evaluation of technology associated with antimatter-derived propulsion. One enabling technology for such experiments is portable storage of low energy antiprotons, allowing antiprotons to be trapped, stored, and transported for use at an experimental facility.

Many space propulsion concepts exist that use matter-antimatter reactions. Current antiproton production rates are enough to conduct proof-of-principle evaluation of these concepts. One enabling technology for such experiments is portable storage of low energy antiprotons, to transport antiprotons to experimental facilities. To address this need, HiPAT is being developed, with a design goal of containing 10(exp 12) particles for up to 18 days. HiPAT is a Penning-Malmberg trap with a 4 Tesla superconductor, 20kV electrodes, radio frequency (RF) network, and 10(exp -13) Torr vacuum. 'Normal' matter is being used to evaluate the system. An electron beam ionizes background gas in situ, and particle beams are captured dynamically. The experiment examines ion storage lifetimes, RF plasma diagnostics, charge exchange with background gases, and dynamic ion beam capture.

The behavior of hydrogen ion clusters is tested by an inject/hold/extract technique in a Penning-Malmberg trap. The timing pattern of the extraction signals is consistent with the clusters bouncing elastically from a detector several times. The ion clusters behave more like an elastic fluid than a beam of ions.

The annihilation of antimatter provides the highest mass specific energy of any other known reaction. Proper harnessing of this energy holds great promise for future space propulsion systems. Many different propulsion concepts have been proposed that take advantage of antimatter, either using matter-antimatter as the primary fuel, or as a 'spark plug' for fusion and fission systems. In order to begin to address these concepts experimentally, a method of storing and transporting antimatter must be developed. The High Performance Antiproton Trap (HiPAT) is a first-generation storage and transportation device designed to store and transport 10(exp 12) antiprotons with a storage half-life of 18 days. It uses a Penning-Malmberg ion trap with a 4T magnetic field and 20 kV potential. This will enable researchers much more flexibility in the design of antimatter experiments related to propulsion. Ions cannot be stored indefinitely in a real trap, as ion cloud instabilities develop from imperfections in manufacturing and misalignments in assembly. Previous work has been done at both the National Institute of Standards and University of California in San Diego in using RF (radio frequency) signals to both diagnose and confine the ion cloud. Two electrodes in the trap have been segmented to allow both reception and transmission of RF waves in the ion cloud. Experiments are underway to determine the number of ions and density in the cloud by "listening" to protons contained in the HiPAT. Currently we believe the density of ions stored in the trap is roughly 10(exp 15) m(exp -3). Development of non-destructive techniques is vital to the project goals, enabling continuous monitoring of the quantities stored in the system. Experimental work is also being done in identifying RF transmission frequencies that can manipulate the density of the cloud, by exchanging energy and momentum between the RF wave and the ions. Preliminary experiments have demonstrated this interaction.

The NASA/Marshall Space Flight Centers (NASA/MSFC) Propulsion Research Center (PRC) is evaluating an antiproton storage system, referred to as the High Performance Antiproton Trap (HiPAT). This interest stems from the sheer energy represented by matter/antimatter annihilation process with has an energy density approximately 10 order of magnitude above that of chemical propellants. In other terms, one gram of antiprotons contains the equivalent energy of approximately 23 space shuttle external tanks or ET's (each ET contains roughly 740,000 kgs of fuel and oxidizer). This incredible source of stored energy, if harnessed, would be an enabling technology for deep space mission where both spacecraft weight and propulsion performance are key to satisfying aggressive mission requirements. The HiPAT hardware consists of a 4 Tesla superconductor system, an ultra high vacuum test section (vacuum approaching 10(exp -12) torr), and a high voltage confinement electrode system (up to 20 kvolts operation). The current laboratory layout is illustrated. The HiPAT designed objectives included storage of up to 1 trillion antiprotons with corresponding lifetimes approaching 18 days. To date, testing has centered on the storage of positive hydrogen ions produced in situ by a stream of high-energy electrons that passes through the trapping region. However, due to space charge issues and electron beam compression as it passes through the HiPAT central field, current ion production is limited to less then 50,000 ions. Ion lifetime was determined by counting particle populations at the end of various storage time intervals. Particle detection was accomplished by destructively expelling the ions against a micro-channel plate located just outside the traps magnetic field. The effect of radio frequency (RF) stabilization on the lifetime of trapped particles was also examined. This technique, referred to as a rotating wall, made use of a segmented electrode located near the center of the trap on which various phases of a particular frequency were applied. Various experiments were performed illustrating the ability of an RF drive to both prolong and reduced the lifetimes of various ion species depending on the selected frequency. HiPAT is now being reconfigured for testing with an ion source that will provide both positive and negative hydrogen ions from an external source. This ion system shall provide higher fill capacity (order of million of ions per shot), stacking of multiple shots, and injection schemes typical of a realistic antiproton delivery system.

Successful development of space fission systems requires 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. 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 non-nuclear testing. Through demonstration of systems concepts (designed by DOE National Laboratories) in relevant environments, this philosophy has been demonstrated through hardware testing in the High Power Propulsion Thermal Simulator (HPPTS). The HPPTS is designed to enable very realistic non-nuclear testing of space fission systems. Ongoing research at the HPPTS is geared towards facilitating research, development, system integration, and system utilization via cooperative efforts with DOE labs, industry, universities, and other NASA centers. Through hardware based design and testing, the HPPTS investigates High Power Electric Propulsion (HPEP) component, subsystem, and integrated system design and performance.

The annihilation of matter with antimatter represents the highest energy density of any known reaction, producing 10(exp 8) MJ/g, approximately 10 orders of magnitude more energy per unit mass than chemical based combustion. To take the first step towards using this energy for propulsion applications the NASA MSFC Propulsion Research Center (PRC) has initiated a research activity examining the storage of low energy antiprotons. Storage was identified as a key enabling technology since it builds the experience base necessary to understand the handling of antiprotons for virtually all utilization and high-density storage concepts. To address this need, a device referred to as the High Performance Antiproton Trap (HiPAT) is under development at the NASA MSFC PRC. The HiPAT is an electromagnetic system (Penning-Malmberg design) consisting of a 4 Tesla superconductor, a high voltage confinement electrode system (operation up to 20 KV), and an ultra high vacuum test section (operating in the 10(exp -12) torr range). The system was designed to be portable with an ultimate goal of maintaining 10(exp 12) charged particles with a half-life of 18 days. Currently, this system is being experimentally evaluated using normal matter ions which are cheap to produce and relatively easy to handle. These normal ions provide a good indication of overall trap behavior, with the exception of assessing annihilation losses. The ions are produced external to HiPAT using two hydrogen ion sources, with adjustable beam energy and current. Ion are transported in a beam line and controlled through the use of electrostatic optics. These optics serve to both focus and gate the incoming ions, providing microsecond-timed pulses that are dynamically captured by cycling the HiPAT electric containment field like a 'trap door'. The layout of this system more closely simulates the operations expected at an actual antiproton production facility where 'packets' of antiprotons with pulse widths measured in 100's of nanoseconds could be provided. Initial dynamic capture experiments have been performed with both trap and ton source system functioning at approximately 10% of maximum levels, minimizing the potential for extraneous effects. Dynamic trapping techniques demonstrated the successful capture of millions of hydrogen ions with good agreement with the predicted loading based on the timing sequence, trap electric field, and ion beam current. These techniques will be expanded to examine multiple shot capture or 'stacking' to increase the total number of ions stored within HiPAT.

Cryogenic fluid management (CFM) is a technology area common to virtually every space transportation propulsion concept envisioned. Storage, supply, transfer and handling of sub-critical cryogenic fluids are basic capabilities that have long been needed by multiple programs and the need is expected to continue in the future. The use of magnetic fields provides another method, which could replace or augment current/traditional approaches, potentially simplifying vehicle operational constraints. The magnetically actuated propellant orientation (MAPO) program effort focused on the use of magnetic fields to control fluid motion as it relates to positioning (i.e. orientation and acquisition) of a paramagnetic substance such as LO2. Current CFM state- of-the-art systems used to control and acquire propellant in low gravity environments rely on liquid surface tension devices which employ vanes, fine screen mesh channels and baskets. These devices trap and direct propellant to areas where it's needed and have been used routinely with storable (non-cryogenic) propellants. However, almost no data exists r,egarding their operation in cryogenics and the use of such devices confronts designers with a multitude of significant technology issues. Typical problems include a sensitivity to screen dry out (due to thermal loads and pressurant gas) and momentary adverse accelerations (generated from either internal or external sources). Any of these problems can potentially cause the acquisition systems to ingest or develop vapor and fail. The use of lightweight high field strength magnets may offer a valuable means of augmenting traditional systems potentially mitigating or at least easing operational requirements. Two potential uses of magnetic fields include: 1) strategically positioning magnets to keep vent ports clear of liquid (enabling low G vented fill operations), and 2) placing magnets in the center or around the walls of the tank to create an insulating vapor pocket (between the liquid and the tank wall) which could effectively lower heat transfer to the liquid (enabling increased storage time).

Advanced space transportation options may eventually enable rapid, affordable access to any point in the solar system. Advanced propulsion systems with energy densities several orders of magnitude greater than state-of-the art systems may be available in the 21 st century. These propulsion systems include systems based on fission, fusion, antimatter annihilation and other advanced processes. Other transportation options propose using in-situ resources to enable rapid, affordable access to any point in the solar system using more conventional propulsion technologies. This presentation will summarize select space transportation options of current interest to NASA MSFC's Space Propulsion Branch, present progress being made towards developing each of the options, and discuss obstacles that must be overcome before any of the options can be implemented.

Foam multilayer insulation (FMLI), a reusable thermal control system (TCS), was evaluated in a simulated orbit hold environment on a test tank of 3.0 ft diameter, 5.6 ft length, and 34.5 cu ft volume. The TCS consisted of a 0.44-inch thick foam and a 16-layer (17 sheet) MLI blanket attached to the tank barrel and lower bulkhead, with the upper bulkhead covered with a 2.7-inch foam and a 31-layer (32 sheets) MLI blanket. Average insulation heating rates during orbit hold simulations ranged from 10.5 to 28.1 Btu/hr for warm boundary temperatures from 300 to 460 R, respectively. These rates corresponded to liquid losses of 0.9 and 2.3 percent of the tank's volume per day. This liquid loss rate would be significantly reduced for full size vehicle tanks due to the decreased surface area-to-volume ratio as compared to the test tank.

NASA-Marshall has devised an upper-stage vehicle-applicable reusable cryogenic insulation thermal-control system which employs spray-on foam insulation (SOFI) that is attached to the cryotank wall and covered by 17-sheet multilayer insulation composed of double-aluminized mylar and Dacron scrim. Four prelaunch test simulations have been conducted for the case of LH2 with gaseous N2 purge gas. Test results indicate that the SOFI surface temperature was sufficiently high to preclude atmospheric oxygen and nitrogen liquefaction.

Predictions of a CFD program calculating a fluid-free surface shape and motion as a function of imposed acceleration are validated against the drop-tower test data collected to support design and performance assessments of the Saturn S-IVB stage liquid-hydrogen tank. The drop-tower facility, experimental package, and experiment procedures are outlined, and the program is described. It is noted that the validation analysis confirms the program's suitability for predicting low-g fluid slosh behavior, and that a similar analysis could examine the effect of incorporating baffles and screens to impede initiation of any unwanted side loads due to slosh. It is concluded that in actual vehicle applications, the engine thrust tailoff profile should be included in computer simulations if the precise interface versus time definition is needed.