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Spacecraft thermal control systems are essential to provide the necessary thermal environment for the crew and to ensure that the equipment functions adequately on space missions. The Ultralight Fabric Reflux Tube (UFRT) was developed by the Pacific Northwest National Laboratory as a lightweight radiator concept to be used on planetary surface-type missions (e.g., Moon, Mars). The UFRT consists of a thin-walled tube (acting as the fluid boundary), overwrapped with a low-mass ceramic fabric (acting as the primary pressure boundary). The tubes are placed in an array in the vertical position with the evaporators at the lower end. Heat is added to the evaporators, which vaporizes the working fluid. The vapor travels to the condenser end section and condenses on the inner wall of the thin-walled tube. The resulting latent heat is radiated to the environment. The fluid condensed on the tube wall is then returned to the evaporator by gravity.

A porous plate sublimator (based on an existing Lunar Module LM-209 design) is baselined as a heat rejection device for the X-38 vehicle due to its simplicity, reliability, and flight readiness. The sublimator is a passive device used for rejecting heat to the vacuum of space by sublimating water to obtain efficient heat rejection in excess of 1,000 Btu/lb of water. It is ideally suited for the X-38/CRV mission as it requires no active control, has no moving parts, has 100% water usage efficiency, and is a well-proven technology. Two sublimators have been built and tested for the X-38 program, one of which will fly on the NASA V-201 space flight demonstrator vehicle in 2001. The units satisfied all X-38 requirements with margin and have demonstrated excellent performance. Minor design changes were made to the LM-209 design for improved manufacturability and parts obsolescence.

Hamilton Sundstrand has developed a scalable evaporative heat rejection system called the Multi-Fluid Evaporator (MFE). It was designed to support the Orion Crew Module and to support future Constellation missions. The MFE would be used from Earth sea level conditions to the vacuum of space. This system combines the functions of the Space Shuttle flash evaporator and ammonia boiler into a single compact package with improved freeze-up protection. The heat exchanger core is designed so that radial flow of the evaporant provides increasing surface area to keep the back pressure low. The multiple layer construction of the core allows for efficient scale up to the desired heat rejection rate. A full-scale unit uses multiple core sections that, combined with a novel control scheme, manage the risk of freezing the heat exchanger cores. A four-core MFE prototype was built in 2007.

Hamilton Sundstrand is under contract with the NASA Johnson Space Center to develop a scalable, evaporative heat rejection system called the Multi-Fluid Evaporator (MFE). It is being designed to support the Orion Crew Module and to support future Constellation missions. A MFE would be used from Earth sea level conditions to the vacuum of space. The current Space Shuttle configuration utilizes an ammonia boiler and flash evaporator system to achieve cooling at all altitudes. With the MFE system, both functions are combined into a single compact package with significant weight reduction and improved freeze-up protection. The heat exchanger core is designed so that radial flow of the evaporant provides increasing cross-sectional area to keep the back pressure low. Its multiple layer construction allows for efficient scale up to the desired heat rejection rate.

In a crewed spacecraft environment, atmospheric carbon dioxide (CO2) and moisture control are crucial. Hamilton Sundstrand has developed a stable and efficient amine-based CO2 and water vapor sorbent, SA9T, that is well suited for use in a spacecraft environment. The sorbent is efficiently packaged in pressure-swing regenerable beds that are thermally linked to improve removal efficiency and minimize vehicle thermal loads. Flows are all controlled with a single spool valve. This technology has been baselined for the new Orion spacecraft. However, more data was needed on the operational characteristics of the package in a simulated spacecraft environment. A unit was therefore tested with simulated metabolic loads in a closed chamber at Johnson Space Center during the last third of 2006. Tests were run at a variety of cabin temperatures and with a range of operating conditions varying cycle time, vacuum pressure, air flow rate, and crew activity levels.

The NASA Johnson Space Center has plans to integrate a Solid Amine Water Desorbed (SAWD II) carbon dioxide removal subsystem into the Variable Pressure Growth Chamber (VPGC). The SAWD II subsystem will be used to remove any excess carbon dioxide (CO2) input into the VPGC which is not assimilated by the plants growing in the chamber. An analysis of the integrated VPGC-SAWD II system was performed using a mathematical model of the system implemented in the Computer-Aided System Engineering and Analysis (CASE/A) package. The analysis consisted of an evaluation of the SAWD II subsystem configuration within the VPGC, the planned operations for the subsystem, and the overall performance of the subsystem and other VPGC subsystems. Based on the model runs, recommendations were made concerning the SAWD II subsystem configuration and operations, and the chambers' automatic CO2 injection control subsystem.

The Space Station provides a unique facility for conducting material processing and life science experiments under microgravity conditions. These conditions place special requirements on the U.S. Laboratory for storing and transporting chemicals and process fluids, reclaiming water from selected experiments, treating and storing experiment wastes, and providing vacuum utilities. To meet these needs and provide a safe laboratory environment, the Process Material Management System (PMMS) is being developed. Preliminary design requirements and concepts related to the PMMS are addressed in addition to discussing the MSFC PMMS breadboard test facility and a preliminary plan for validating the overall system design. The system contains a fluid handling subsystem which manages process fluids required by each experiment while a chemical storage facility safely stores potentially hazardous chemicals.

The Orion crew module (CM) is being designed to perform survivable land and water landings. There are many issues associated with post-landing crew survival. In general, the most challenging of the realistic Orion landing scenarios from an environmental control standpoint is the off-nominal water landing. Available power and other consumables will be very limited after landing, and it may not be possible to provide full environmental control within the crew cabin for very long after splashdown. Given the bulk and thermal insulation characteristics of the crew-worn pressure suits, landing in a warm tropical ocean area would pose a risk to crew survival from elevated core body temperatures, if for some reason the crewmembers were not able to remove their suits and/or exit the vehicle. This paper summarizes the analyses performed and conclusions reached regarding post-landing crew survival following a water landing, from the standpoint of the crew's core body temperatures.

To date, 59 man-EVA's have been conducted in the Shuttle Program with minimum physiological problems or limitations. The physiological requirements for life support in the Shuttle EVA include pressure, gas composition, inspired CO2 pressure, heat- removal capability, in-suit water replacement, and caloric replacement. These requirements and their basis in verification testing or analysis are reviewed. The operational measures are identified. The suit pressure in combination with a gas composition of at least 92 percent assures that sufficient O2 pressure is available to the crewmember. The nominal suit pressure of 4.3 psi±0.1 psi was maintained during all 59 man-EVA's. The contingency suit pressure was never required to be used. The suit pressure in combination with the cabin pressure and pre-EVA denitrogenation procedures minimize the risk of altitude decompression sickness. There has been no incidence of decompression sickness during Shuttle EVA.

The projections of increased Extravehicular Activity (EVA) operations for the Space Station Freedom (SSF) resulted in the development of advanced space suit technologies to increase EVA efficiency. To eliminate the overhead of denitrogenation, candidate higher-operating pressure suit technologies were developed. The AX-5 all metallic, multi-bearing technologies were developed at the Ames Research Center, and the Mk. III fabric and metallic technologies were developed at the Johnson Space Center. Following initial technology development, extensive tests and analyses were performed to evaluate all aspects of candidate technology performance. The current Space Shuttle space suit technologies were used as a baseline for evaluating those of the AX-5 and Mk. III. Tests included manned evaluations in the Weightless Environment Training Facility and KC-135 zero-gravity aircraft.

CO2 removal, recovery and reduction are essential processes for a closed loop air revitalization system in a crewed spacecraft. Typically, a compressor is required to recover the low pressure CO2 that is being removed from the spacecraft in a swing bed adsorption system. This paper describes integrated tests of a Temperature-Swing Adsorption Compressor (TSAC) with high-fidelity systems for carbon dioxide removal and reduction assemblies (CDRA and Sabatier reactor). It also provides details of the TSAC operation at various CO2 loadings. The TSAC is a solid-state compressor that has the capability to remove CO2 from a low-pressure source, and subsequently store, compress, and deliver it at a higher pressure. TSAC utilizes the principle of temperature-swing adsorption compression and has no rapidly moving parts.

The Major Constituent Analyzer (MCA) was activated on-orbit on 2/13/01 and provided essentially continuous readings of partial pressures for oxygen, nitrogen, carbon dioxide, methane, hydrogen and water in the ISS atmosphere. The MCA plays a crucial role in the operation of the Laboratory ECLSS and EVA operations from the airlock. This paper discusses the performance of the MCA as compared to specified accuracy requirements. The MCA has an on-board self-calibration capability and the frequency of this calibration could be relaxed with the level of instrument stability observed on-orbit. This paper also discusses anomalies the MCA experienced during the first year of on-orbit operation. Extensive Built In Test (BIT) and fault isolation capabilities proved to be invaluable in isolating the causes of anomalies. The process of fault isolation is discussed along with development of workaround solutions and implementation of permanent on-orbit corrections.

Gas-separation and reverse-osmosis membrane models are being developed in conjunction with membrane testing at NASA JSC. The completed gas-separation membrane model extracts effective component permeabilities from multicomponent test data, and predicts the effects of flow configuration, operating conditions, and membrane dimensions on module performance. Variable feed- and permeate-side pressures are considered. The model has been applied to test data for hollow-fiber membrane modules with simulated cabin-air feeds. Results are presented for a membrane designed for air drying applications. Extracted permeabilities are used to predict the effect of operating conditions on water enrichment in the permeate. A first-order reverse-osmosis model has been applied to test data for spiral wound membrane modules with a simulated hygiene water feed. The model estimates an effective local component rejection coefficient under pseudo-steady-state conditions.

On June 25, 1997 a docking mishap of a Progress supply ship caused the Progress vehicle to crash into an array of solar panels and puncture the hull of the Spektr module. The puncture was small enough to allow the crew to seal off the Spektr module and repressurize the rest of the station. The Progress vehicle struck the Spektr module several times and the exact location, size, and number of punctures in the Spektr hull was unknown. Russian cosmonauts donned space suits and went inside the Spektr module to repair some electrical power cables and look for the location of the hull breach, they could not identify the exact location of the hole (or holes). The Spektr module was pressurized with Mir cabin air twice during the STS-86 fly around in an attempt to detect leakage (in the form of ice particles) from the module. Seven particles were observed within a 36 second time span, but tracking the path of the individual particles did not pinpoint a specific leak location.

In a crewed spacecraft environment, atmospheric carbon dioxide (CO2) and moisture control are crucial. Hamilton Sundstrand has developed a stable and efficient amine-based CO2 and water vapor sorbent, SA9T, that is well suited for use in a spacecraft environment. The sorbent is efficiently packaged in pressure-swing regenerable beds that are thermally linked to improve removal efficiency and minimize vehicle thermal loads. Flows are controlled with a single spool valve. This technology has been baselined for the new Orion spacecraft, but additional data was needed on the operational characteristics of the package in a simulated spacecraft environment. One unit was tested with simulated metabolic loads in a closed chamber at Johnson Space Center during the latter part of 2006. Those test results were reported in a 2007 ICES paper.

This ground-based study compared the risk of microbubbles during decompression under simulated space extravehicular activities (EVA) after three days of six-degree head-down bed rest with three days of ambulatory control. Test subjects were exposed to a pressure of 44.8 kPa (6.5 psi), breathed 100% oxygen, and exercised at reduced pressure either in the supine (during experimental) or upright (control) position. Circulating microbubbles were monitored by a precordial Doppler ultrasound device, and were found in 52% (12/23) of control and 26% (6/23) of experimental exposures. Survival analysis using Cox proportional hazards regression showed that there was 0.22 times (95% confidence interval=0.07-0.68) reduction in the risk of high grade microbubbles after bed rest, compared to controls (p=0.004). This finding is of importance in evaluating the risk of DCS during EVA.

An evaporative heat sink has been designed and built by AlliedSignal for NASA's Johnson Space Center. The unit is a demonstrator of a primary heat exchanger for NASA's prototype Crew Return Vehicle (CRV), designated the X-38. The primary heat exchanger is responsible for rejecting the heat produced by both the flight crew and the avionics. Spacecraft evaporative heat sinks utilize space vacuum as a resource to control the vapor pressure of a liquid. For the X-38, water has been chosen as the heat transport fluid. A portion of this coolant flow is bled off for use as the evaporant. At sufficiently low pressures, the water can be made to boil at temperatures approaching its freezing point. Heat transferred to liquid water in this state will cause the liquid to evaporate, thus creating a heat sink for the spacecraft's coolant loop. The CRV mission requires the heat exchanger to be compact and low in mass.

Future NASA manned missions to the moon and Mars will require development of robust regenerative life support system technologies which offer high reliability and minimal resupply. To support the development of such systems, early ground-based test facilities will be required to demonstrate integrated, long-duration performance of candidate regenerative air revitalization, water recovery, and thermal management systems. The advanced life support Systems Integration Research Facility (SIRF) is one such test facility currently being developed at NASA's Johnson Space Center (JSC). The SIRF, when completed, will accommodate unmanned and subsequently manned integrated testing of advanced regenerative life support technologies at ambient and reduced atmospheric pressures.

Metabolically produced carbon dioxide (CO2) removal in spacesuit applications has traditionally been accomplished utilizing non-regenerative Lithium Hydroxide (LiOH) canisters. In recent years, regenerative Metal Oxide (MetOx) has been developed to replace the Extravehicular Mobility Unity (EMU) LiOH canister for extravehicular activity (EVA) missions in micro-gravity, however, MetOx may carry a significant weight burden for potential use in future Lunar or planetary EVA exploration missions. Additionally, both of these methods of CO2 removal have a finite capacity sized for the particular mission profile. Metabolically produced water vapor removal in spacesuits has historically been accomplished by a condensing heat exchanger within the ventilation process loop of the suit life support system.

During the period July 2001 to March 2002, the performance of a water-jacketed high intensity discharge lamp of advanced design was evaluated within a lamp test stand at The University of Arizona (UA), Controlled Environment Agriculture Center (CEAC) in Tucson, Arizona. The lamps and test stand system were developed by Mr. Phil Sadler of Sadler Machine Company, Tempe, Arizona, and supported by a Space Act Agreement between NASA-Johnson Space Center (JSC) and UA. The purpose was for long term testing of the prototype lamp and demonstration of an improved procedure for use of water-jacketed lamps for plant production within the close confines of controlled environment facilities envisioned by NASA within Bioregenerative Life Support Systems. The lamp test stand consisted of six, 400 watt water-cooled, high pressure sodium HID lamps, mounted within a framework.