Darby B. Makel

Case Studies in Chemical Sensor Development

The need for chemical sensor technology has increased in recent years generating the need for the development of new, advanced sensor technology. This book chapter provides a series of case studies related to the development and application of chemical sensors centering on microfabricated sensors for aerospace applications. Each case study discusses the development of a sensor or sensor system, including technology challenges, and illustrates a major theme related to chemical sensor development. These major themes suggest possible strategies that can be employed to address technical challenges in the area of sensor development. The chapter closes with a discussion that goes beyond sensor development to application approaches for including sensor technology into operating systems. It is concluded that sensor technology distributed throughout the vehicle with attributes such as ease of use, reliability, and orthogonality can significantly advance intelligent systems

INTELLIGENT CHEMICAL SENSOR SYSTEMS FOR IN-SPACE SAFETY APPLICATIONS

Future in-space and lunar operations will require significantly improved monitoring and Integrated System Health Management (ISHM) throughout the mission. In particular, the monitoring of chemical species is an important component of an overall monitoring system for space vehicles and operations. For example, in leak monitoring of propulsion systems during launch, inspace, and on lunar surfaces, detection of low concentrations of hydrogen and other fuels is important to avoid explosive conditions that could harm personnel and damage the vehicle. Dependable vehicle operation also depends on the timely and accurate measurement of these leaks. Thus, the development of a sensor array to determine the concentration of fuels such as hydrogen, hydrocarbons, or hydrazine as well as oxygen is necessary. Work has been on-going to develop an integrated smart leak detection system based on miniaturized sensors to detect hydrogen, hydrocarbons, or hydrazine, and oxygen. The approach is to implement Microelectromechanical Systems (MEMS) based sensors incorporated with signal conditioning electronics, power, data storage, and telemetry enabling intelligent systems. The final sensor system will be self-contained with a surface area comparable to a postage stamp. This paper discusses the development of this “Lick and Stick” leak detection system and it’s application to In-Space Transportation and other Exploration applications.

A hydrogen leak detection system for aerospace and commercial applications

Leaks on the space shuttle while on the launch pad have generated interest in hydrogen leak monitoring technology. Microfabricated hydrogen sensors are being fabricated at Case Western Reserve University (CWRU) and tested at NASA Lewis Research Center (LeRC). These sensors have been integrated into hardware and software designed by Aerojet. This complete system allows for multipoint leak monitoring designed to provide leak source and magnitude information in real time. The monitoring system processes data from the hydrogen sensors and presents the operator with a visual indication of the leak location and magnitude. Although the leak monitoring system was designed for hydrogen propulsion systems, the possible applications of this monitoring system are wide ranged. This system is in operation in an automotive application which requires high sensitivity to hydrogen.

The development of micro/nano chemical sensor systems for aerospace applications

Aerospace applications require a range of chemical sensing technologies to monitor conditions related to both space exploration and aeronautic aircraft operations. These applications include leak detection, engine emissions monitoring, fire detection, human health monitoring, and environmental monitoring. This paper discusses efforts to produce microsensor platforms and Smart Sensor Systems that can be tailored to measure a range of chemical species. This technology development ranges from development of base sensor platforms to the evaluation of more mature systems in relevant environments. Although microsensor systems can have a significant impact on aerospace applications, extensive application testing is necessary for their long-term implementation. The introduction of nanomaterials into microsensor platforms has the potential to significantly enable improved sensor performance, but control of those nanostructures is necessary in order to achieve maximum benefits. Examples will be given of microsensor platform technology, Smart Sensor Systems, application testing, and efforts to integrate and control nanostructures into sensor structures.

Microfabricated Hydrogen Sensor Technology for Aerospace and Commercial Applications

Leaks on the Space Shuttle while on the Launch Pad have generated interest in hydrogen leak monitoring technology. An effective leak monitoring system requires reliable hydrogen sensors, hardware, and software to monitor the sensors. The system should process the sensor outputs and provide real-time leak monitoring information to the operator. This paper discusses the progress in developing such a complete leak monitoring system. Advanced microfabricated hydrogen sensors are being fabricated at Case Western Reserve University (CWRU) and tested at NASA Lewis Research Center (LeRC) and Gencorp Aerojet (Aerojet). Changes in the hydrogen concentrations are detected using a PdAg on silicon Schottky diode structure. Sensor temperature control is achieved with a temperature sensor and heater fabricated onto the sensor chip. Results of the characterization of these sensors are presented. These sensors can detect low concentrations of hydrogen in inert environments with high sensitivity and quick response time. Aerojet is developing the hardware and software for a multipoint leak monitoring system designed to provide leak source and magnitude information in real time. The monitoring system processes data from the hydrogen sensors and presents the operator with a visual indication of the leak location and magnitude. Work has commenced on integrating the NASA LeRC-CWRU hydrogen sensors with the Aerojet designed monitoring system. Although the leak monitoring system was designed for hydrogen propulsion systems, the possible applications of this monitoring system are wide ranged. Possible commercialization of the system will also be discussed.

Materials Combustion Testing and Combustion Product Sensor Evaluations in FY12

NASA Centers continue to collaborate to characterize the chemical species and smoke particles generated by the combustion of current space-rated non-metallic materials including fluoropolymers. This paper describes the results of tests conducted February through September 2012 to identify optimal chemical markers both for augmenting particle-based fire detection methods and for monitoring the post-fire cleanup phase in human spacecraft. These studies follow up on testing conducted in August 2010 and reported at ICES 2011. The tests were conducted at the NASA White Sands Test Facility in a custom glove box designed for burning fractional gram quantities of materials under varying heating profiles. The 623 L chamber was heavily instrumented to quantify organics (gas chromatography/mass spectrometry), inorganics by water extraction followed by ion chromatography, and select species by various individual commercially-available sensors. Evaluating new technologies for measuring carbon monoxide, hydrogen cyanide, hydrogen fluoride, hydrogen chloride and other species of interest was a key objective of the test. Some of these sensors were located inside the glovebox near the fire source to avoid losses through the sampling lines; the rest were located just outside the glovebox. Instruments for smoke particle characterization included a Tapered Element Oscillating Microbalance Personal Dust Monitor (TEOM PDM) and a TSI Dust Trak DRX to measure particle mass concentration, a TSI PTrak for number concentration and a thermal precipitator for collection of particles for microscopic analysis. Materials studied included Nomex(R), M22759 wire insulation, granulated circuit board, polyvinyl chloride (PVC), Polytetrafluoroethylene (PTFE), Kapton(R), and mixtures of PTFE and Kapton(R). Furnace temperatures ranged from 340 to 640 C, focusing on the smoldering regime. Of particular interest in these tests was confirming burn repeatability and production of acid gases with different fuel mixture compositions, as well as the dependence of aerosol concentrations on temperature.

In Situ Manufacturing of Plastics and Composites to Support H&R Exploration

With the new direction of NASA to emphasize the exploration of the Moon, Mars and beyond, quick development and demonstration of efficient systems for In Situ Resources Utilization (ISRU) is more critical and timely than ever before. Beyond the production of life support consumables or propellants, long term missions will require much greater levels of utilization of indigenous resources, including fabrication of habitats, radiation shielding, and replacement parts and tools. This paper reports the development of a reactor system for the synthesis of polyethylene from carbon dioxide and water. One technology commonly found in most NASA In Situ Resources Utilization scenarios is the use of the Sabatier reaction and water electrolysis to produce methane and oxygen. The system presented uses methane and oxygen to produce ethylene, and subsequently ethylene is polymerized to produce polyethylene. The process selected enables the synthesis of high‐density polyethylene suitable for the fabrication of many produ...

Microchannel Reactors for ISRU Applications

Affordable planning and execution of prolonged manned space missions depend upon the utilization of local resources and the waste products which are formed in manned spacecraft and surface bases. Successful in‐situ resources utilization (ISRU) will require component technologies which provide optimal size, weight, volume, and power efficiency. Microchannel reactors enable the efficient chemical processing of in situ resources. The reactors can be designed for the processes that generate the most benefit for each mission. For instance, propellants (methane) can be produced from carbon dioxide from the Mars atmosphere using the Sabatier reaction and ethylene can be produced from the partial oxidation of methane. A system that synthesizes ethylene could be the precursor for systems to synthesize ethanol and polyethylene. Ethanol can be used as a nutrient for Astrobiology experiments, as well as the production of nutrients for human crew (e.g. sugars). Polyethylene can be used in the construction of habitats, tools, and replacement parts. This paper will present recent developments in miniature chemical reactors using advanced Micro Electro Mechanical Systems (MEMS) and microchannel technology to support ISRU of Mars and lunar missions. Among other applications, the technology has been demonstrated for the Sabatier process and for the partial oxidation of methane. Microchannel reactors were developed based on ceramic substrates as well as metal substrates. In both types of reactors, multiple layers coated with catalytic material are bonded, forming a monolithic structure. Such reactors are readily scalable with the incorporation of extra layers. In addition, this reactor structure minimizes pressure drop and catalyst settling, which are common problems in conventional packed bed reactors.Affordable planning and execution of prolonged manned space missions depend upon the utilization of local resources and the waste products which are formed in manned spacecraft and surface bases. Successful in‐situ resources utilization (ISRU) will require component technologies which provide optimal size, weight, volume, and power efficiency. Microchannel reactors enable the efficient chemical processing of in situ resources. The reactors can be designed for the processes that generate the most benefit for each mission. For instance, propellants (methane) can be produced from carbon dioxide from the Mars atmosphere using the Sabatier reaction and ethylene can be produced from the partial oxidation of methane. A system that synthesizes ethylene could be the precursor for systems to synthesize ethanol and polyethylene. Ethanol can be used as a nutrient for Astrobiology experiments, as well as the production of nutrients for human crew (e.g. sugars). Polyethylene can be used in the construction of habitats,...

Aircraft Ground Demonstration of Engine Emissions Monitoring System Based on a Gas Microsensor Array

This paper presents a gas microsensor array for monitoring the emissions produced by an aircraft engine. This engine emissions monitoring system, which is intended for on-board engine implementation, includes the capability to measure multiple emission byproducts. The intent is to use this emissions information to assist in assessing the health state of the engine, including the diagnosis of engine deterioration and faults. Results from the application of the system to an aircraft turbofan engine are presented and discussed. This includes both nominal engine operating scenarios and seeded fault scenarios. The system is shown to hold promise for detecting the existence of a simulated oil leak as well as bleed actuator faults. Follow-on maturation plans are also discussed.

MicroChannel Reactors for ISRU Applications Using Nanofabricated Catalysts

With the new direction of NASA to emphasize the exploration of the Moon, Mars and beyond, quick development and demonstration of efficient systems for In‐Situ Resources Utilization (ISRU) is more critical and timely than ever before. Affordable planning and execution of prolonged manned space missions depend upon the utilization of local resources and the waste products which are formed in manned spacecraft and surface bases. This paper presents current development of miniaturized chemical processing systems that combine microchannel reactor design with nanofabricated catalysts. Carbon nanotubes (CNT) are used to produce a nanostructure within microchannel reactors, as support for catalysts. By virtue of their nanoscale dimensions, nanotubes geometrically restrict the catalyst particle size that can be supported upon the tube walls. By confining catalyst particles to sizes smaller than the CNT diameter, a more uniform catalyst particle size distribution may be maintained. The high dispersion permitted by ...