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Significant progress has been made at NASA Ames Research Center in the development of a heat melt compaction device called the Plastic Melt Waste Compactor (PMWC). The PMWC was designed to process wet and dry wastes generated on human space exploration missions. The wastes have a plastic content typically greater than twenty percent. The PMWC removes the water from the waste, reduces the volume, and encapsulates it by melting the plastic constituent of the waste. The PMWC is capable of large volume reductions. The final product is compacted waste disk that is easy to manage and requires minimal crew handling. This paper describes the results of tests conducted using the PMWC with a wet and dry waste composite that was representative of the waste types expected to be encountered on long duration human space exploration missions.

Operational issues encountered by Apollo astronauts relating to lunar dust were catalogued, including material abrasion that resulted in scratches and wear on spacesuit components, ultimately impacting visibility, joint mobility and pressure retention. Standard methods are being developed to measure abrasive wear on candidate construction materials to be used for spacesuits, spacecraft, and robotics. Calibration tests were conducted using a standard diamond stylus scratch tip on the common spacecraft structure aluminum, Al 6061-T6. Custom tips were fabricated from terrestrial counterparts of lunar minerals for scratching Al 6061-T6 and comparing to standard diamond scratches. Considerations are offered for how to apply standards when selecting materials and developing dust mitigation strategies for lunar architecture elements.

The thick oxide layer of silicon-on-insulator (SOI) devices significantly reduces the junction leakage current at elevated temperatures compared to similar Si devices, resulting in an elevated maximum operating temperature. The maximum operating temperature, specified by manufacturers, of commercial SOI devices/circuits with conventional packaging is usually 225°C. It is important to understand the performance and de-ratings of these SOI circuits at temperatures above 225°C without the temperature limit imposed by commercial packaging technology. This work tested a low frequency square-wave oscillator based on an SOI 555 Timer with a special high temperature ceramic packaging technology from room temperature to 375°C. The timer die was attached to a 96% aluminum oxide substrate with high temperature durable gold (Au) thick-film metallization, and interconnected with Au wires.

The Vapor Phase Catalytic Ammonia Removal (VPCAR) system is being developed to recycle water for future NASA Exploration Missions [1,2,3,4,5]. Reduced gravity testing of the VPCAR System has been initiated to identify any potential problems with microgravity operation. Two microgravity testing campaigns have been conducted on NASA's C-9B Reduced Gravity Aircraft. These tests focused on the fluid dynamics of the unit's Wiped-Film Rotating Disk (WFRD) evaporator. The experiments used a simplified system to study the process of forming a thin film on a rotating disk. The configuration simulates the application of feed in the VPCAR's WFRD evaporator. The first round of aircraft testing, which was completed in early 2006, indicated that a problem with microgravity operation of the WFRD existed. It was shown that in reduced gravity the VPCAR wiper did not produce a uniform thin film [6]. The film was thicker near the axis of rotation where centrifugal forces are small.

Spacecraft radiators reject heat to their surroundings. Radiators can be deployable or mounted on the body of the spacecraft. NASA's Crew Exploration Vehicle is to use body mounted radiators. Coatings play an important role in heat rejection. The coatings provide the radiator surface with the desired optical properties of low solar absorptance and high infrared emittance. These specialized surfaces are applied to the radiator panel in a number of ways, including conventional spraying, plasma spraying, or as an appliqué. Not specifically designed for a weathering environment, little is known about the durability of conventional paints, coatings, and appliqués upon exposure to weathering and subsequent exposure to solar wind and ultraviolet radiation exposure. In addition to maintaining their desired optical properties, the coatings must also continue to adhere to the underlying radiator panel.

The least expensive life support for brief human missions is direct supply of all water and oxygen from Earth without any recycling. The currently most advanced human life support system was designed for the International Space Station (ISS) and will use physicochemical systems to recycle water and oxygen. This paper compares physicochemical to direct supply air and water life support systems using Equivalent Mass (EM). EM breakeven dates and EM ratios show that physicochemical systems are more cost effective for longer mission durations.

We present a device for collecting and storing feces in microgravity that is user-friendly yet suitable for spacecraft in which cabin volume and mass are constrained. On Apollo missions, the commode function was served using disposable plastic bags, which proved time-consuming and caused odor problems. On Skylab, the space shuttle, and the International Space Station, toilets have used airflow beneath a seat to control odors and collect feces. We propose to incorporate airflow into a system of self-compacting, self-drying collection and stowage bags, providing the benefits of previous commodes while minimizing mass and volume. Each collection bag consists of an inner layer of hydrophobic membrane that is permeable to air but not liquid or solid waste, an outer layer of impermeable plastic, and a collapsible spacer separating the inner and outer layers. Filled bags are connected to space vacuum, compacting and drying their contents.

This paper considers the design of a life support system for transit to Mars and return to Earth. Because of the extremely high cost of launching mass to Mars, the Mars transit life support system must minimize the amount of oxygen, water, and food transported. The three basic ways to provide life support are to directly supply all oxygen and water, or to recycle them using physicochemical equipment, or to produce them incidentally while growing food using crop plants. Comparing the costs of these three approaches shows that physicochemical recycling of oxygen and water is least costly for a Mars transit mission. The long mission duration also requires that the Mars transit life support system have high reliability and maintainability. Mars transit life support cannot make use of planetary resources or gravity. It should be tested in space on the International Space Station (ISS).

The on-demand production of Medical Grade Water (MGW) is a critical biomedical requirement for future long-duration exploration missions. Potentially, large volumes of MGW may be needed to treat burn victims, with lesser amounts required to reconstitute pharmacological agents for medical preparations and biological experiments, and to formulate parenteral fluids during medical treatment. Storage of MGW is an untenable means to meet this requirement, as are nominal MGW production methods, which use a complex set of processes to remove chemical contaminants, inactivate all microorganisms, and eliminate endotoxins, a toxin originating from gram-negative bacteria cell walls. An innovative microgravity compatible alternative, using a microwave-based MGW generator, is described in this paper. The MGW generator efficiently couples microwaves to a single-phase flowing stream, resulting in super-autoclave temperatures.

In February 2004 NASA released “The Vision for Space Exploration.” The important goals outlined in this document include extending human presence in the solar system culminating in the exploration of Mars. Unprocessed waste poses a biological hazard to crew health and morale. The waste processing methods currently under consideration include incineration, microbial oxidation, pyrolysis and compaction. Although each has advantages, no single method has yet been developed that is safe, recovers valuable resources including oxygen and water, and has low energy and space requirements. Thus, the objective of this project is to develop a low temperature oxidation process to convert waste cleanly and rapidly to carbon dioxide and water. In the Phase I project, TDA Research, Inc. demonstrated the potential of a low temperature oxidation process using ozone. In the current Phase II project, TDA and NASA Ames Research Center are developing a pilot scale low temperature ozone oxidation system.

A steady-state system mass balance calculation was performed to investigate design issues regarding the storage and/or processing of solid waste. In the initial stages of BIO-Plex, only a certain percentage of the food requirement will be satisfied through crop growth. Since some food will be supplied to the system, an equivalent amount of waste will accumulate somewhere in the system. It is a system design choice as to where the mass should accumulate in the system. Here we consider two approaches. One is to let solid waste accumulate in order to reduce the amount of material processing that is needed. The second is to process all of the solid waste to reduce solid waste storage and then either resupply oxygen or add physical/chemical (P/C) processors to recover oxygen from the excess carbon dioxide and water that is produced by the solid waste processor.

Pyrolysis is a very versatile waste processing technology which can be tailored to produce a variety of solid, liquid and/or gaseous products. The pyrolysis processing of pure and mixed solid waste streams has been under investigation for several decades for terrestrial use and a few commercial units have been built for niche applications. Pyrolysis has more recently been considered for the processing of mixed solid wastes in space. While pyrolysis units can easily handle mixed solid waste streams, the dependence of the pyrolysis product distribution on the component composition is not well known. It is often assumed that the waste components (e.g., food, paper, plastic) behave independently, but this is a generalization that can usually only be applied to the overall weight loss and not always to the yields of individual gas species.

Direct osmotic concentration (DOC) is an integrated membrane treatment process designed for the reclamation of spacecraft wastewater. The system includes forward osmosis (FO), membrane evaporation, reverse osmosis (RO) and an aqueous phase catalytic oxidation (APCO) post-treatment unit. This document describes progress in the third year of a four year project to advance hardware maturity of this technology to a level appropriate for human rated testing. The current status of construction and testing of the final deliverable is covered and preliminary calculations of equivalent system mass are funished.

Designers of future space vehicles envision simplifying the Atmosphere Revitalization (AR) system by combining the functions of trace contaminant (TC) control and carbon dioxide removal into one swing-bed system. Flow rates and bed sizes of the TC and CO2 systems have historically been very different. There is uncertainty about the ability of trace contaminant sorbents to adsorb adequately in a high-flow or short bed length configurations, and to desorb adequately during short vacuum exposures. This paper describes preliminary results of a comparative experimental investigation into adsorbents for trace contaminant control. Ammonia sorbents and low temperature catalysts for CO oxidation are the foci. The data will be useful to designers of AR systems for Constellation. Plans for extended and repeated vacuum exposure of ammonia sorbents are also presented.

Oxygen storage and delivery systems for advanced Lunar Exploration Missions are substantially different than those of the International Space Station (ISS) or Apollo missions. The oxygen must be stored without venting for durations of 180 to 210 days prior to use and then used to supply both the steady, low pressure oxygen for the crew, and the higher-pressure oxygen for the extra-vehicular mobility unit. The baseline design is a high pressure gaseous oxygen storage system. Alternate technologies that may offer substantial advantages in terms of the equivalent system mass over the baseline design are being currently evaluated. This study examines both the supercritical and subcritical liquid oxygen storage options, including one with active cooling using a cryocooler. It is found that an actively cooled sub-critical storage system offered the lowest mass system that could satisfy the requirements.

A protocol has been developed that produced the type of lunar soil abrasion damage observed on Apollo spacesuits. This protocol was then applied to four materials (Kevlar®, Vectran®, Orthofabric, and Tyvek®) that are candidates for advanced spacesuits. Three of the four new candidate fabrics (all but Vectran®) were effective at keeping the dust from penetrating to layers beneath. In the cases of Kevlar® and Orthofabric this was accomplished by the addition of a silicone layer. In the case of Tyvek®, the paper structure was dense enough to block dust transport. The least abrasive damage was suffered by the Tyvek®. This was thought to be due in large part to its non-woven paper structure. The woven structures were all abraded where the top of the weave was struck by the abrasive. Of these, the Orthofabric suffered the least wear, with both Vectran® and Kevlar® suffering considerably more extensive filament breakage.

This paper presents results from a smoke detection experiment entitled Smoke Aerosol Measurement Experiment (SAME) which was conducted in the Microgravity Science Glovebox on the International Space Station (ISS) during Expedition 15. Five different materials representative of those found in spacecraft were pyrolyzed at temperatures below the ignition point with conditions controlled to provide repeatable sample surface temperatures and air flow conditions. The sample materials were Teflon®, Kapton®, cellulose, silicone rubber and dibutylphthalate. The transport time from the smoke source to the detector was simulated by holding the smoke in an aging chamber for times ranging from 10 to1800 seconds. Smoke particle samples were collected on Transmission Electron Microscope (TEM) grids for post-flight analysis.

In February 2004 NASA released “The Vision for Space Exploration.” The goals outlined in this document include extending the human presence in the solar system, culminating in the exploration of Mars. A key requirement for this effort is to identify a safe and effective method to process waste. Methods currently under consideration include incineration, microbial oxidation, pyrolysis, drying, and compaction. Although each has advantages, no single method has yet been developed that is safe, recovers valuable resources including oxygen and water, and has low energy and space requirements. Thus, the objective of this work was to develop a low temperature oxidation process to convert waste cleanly and rapidly to carbon dioxide and water. TDA and NASA Ames Research Center have developed a pilot scale low temperature ozone oxidation system to convert organic waste to CO2 and H2O.

This paper present a summary of the design studies for the suit port proof of concept. The Suit Port reduces the need for airlocks by docking the suits directly to a rover or habitat bulkhead. The benefits include reductions in cycle time and consumables traditionally used when transferring from a pressurized compartment to EVA and mitigation of planetary surface dust from entering into the cabin. The design focused on the development of an operational proof of concept evaluated against technical feasibility, level of confidence in design, robustness to environment and failure, and the manufacturability. A future paper will discuss the overall proof of concept and provide results from evaluation testing including gas leakage rates upon completion of the testing program.

This paper describes work that has begun at Ames Research Center on development of a heat melt compactor that can be used on near term and future missions. The heat melt compactor can handle wastes with a significant plastic composition and minimize crew interaction. The current solid waste management system employed on the International Space Station (ISS) consists of compaction, storage, and disposal. Wastes such as plastic food packaging and trash are compacted manually and wrapped in duct taped “footballs” by the astronauts. Much of the waste is simply loaded into the empty Russian Progress spacecraft that is used to bring supplies to ISS. The progress spacecraft and its contents are intentionally burned up in the earth's atmosphere during reentry. This manual method of trash management on ISS is a wasteful use of crew time and does not transition well to far term missions.