Evaluation of Dowfrost(TM) HD as a Thermal Control Fluid for Constellation Vehicles

A test was conducted from November 2008 to January 2009 to help determine the compatibility of an inhibited propylene glycol/water solution with planned Constellation vehicles. Dowfrost(TradeMark) HD was selected as the baseline for Orion, as well as other Constellation systems. Therefore, the same Dowfrost(TradeMark) HD/Water solution planned for Orion was chosen for this test. The fluid was subjected to a thermal fluid loop that had flightlike properties, as compared to Orion. The fluid loop had similar wetted materials, temperatures, flow rates, and aluminum wetted surface area to fluid volume ratio. The test was designed to last for 10 years, the life expectancy of the lunar habitat. However, the test lasted less than two months. System filters became clogged with precipitate, rendering the fluid system inoperable. Upon examination of the precipitate, it was determined that the precipitate composition contained aluminum, which could have only come from materials in the test stand, as aluminum is not part of the Dowfrost(TradeMark HD composition. Also, the fluid pH was determined to have increased from 10.1, at the first test sample, to 12.2, at the completion of the test. This high of a pH is corrosive to aluminum and was certainly a contributing factor to the development of precipitate. Chemical analyses and bench-top tests are currently ongoing to determine the underlying cause for this rapid degradation of the fluid. Hamilton Sundstrand, the contractor developing the Orion thermal fluid loop, is performing a parallel effort to not only understand the cause of fluid degradation in the test, but also to investigate solutions to avoid this problem in the Orion s thermal control system. JSC also consulted with the Hamilton Sundstrand team in the development of this test and the subsequent analysis.