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NASA NTRS2010

Environmental Control and Life Support Integration Strategy for 6-Crew Operations

The International Space Station (ISS) crew complement has increased in size from 3 to 6 crew members. In order to support this increase in crew on ISS, the United States on-orbit Segment (USOS) has been outfitted with a suite of regenerative Environmental Control and Life Support (ECLS) hardware including an Oxygen Generation System (OGS), Waste and Hygiene Compartment (WHC), and a Water Recovery System (WRS). The WRS includes the Urine Processor Assembly (UPA) and the Water Processor Assembly (WPA). With this additional life support hardware, the ISS has achieved full redundancy in its on-orbit life support system between the t OS and Russian Segment (RS). The additional redundancy created by the Regenerative ECLS hardware creates the opportunity for independent support capabilities between segments, and for the first time since the start of ISS, the necessity to revise Life Support strategy agreements. Independent operating strategies coupled with the loss of the Space Shuttle supply and return capabilities in 2010 offer new and unique challenges. This paper will discuss the evolution of the ISS Life Support hardware strategy in support of 6-Crew on ISS, as well as the continued work that is necessary to ensure the support of crew and ISS Program objectives through the life of station

Duchesne, Stephanie M.↗
NASA NTRS2010

Enhanced Microbial Detection Capabilities by a Rapid Portable Instrument

We present data describing a progression of continuing technology development - from expanding the detection capabilities of the current PTS unit to re-outfitting the instrument with a protein microarray increasing the number of detectable compounds. To illustrate the adaptability of the cartridge format, on-orbit operations data from the ISS demonstrate the detection of the fungal cell wall compound beta-glucan using applicable LOCAD-PTS cartridges. LOCAD-PTS is a handheld device consisting of a spectrophotometer, an onboard pumping mechanism, and data storage capabilities. A suite of interchangeable cartridges lined with four distinct capillaries allow a hydrated sample to mix with necessary reagents in the channels before being pumped to the optical well for spectrophotometric analysis. The reagents housed in one type of cartridge trigger a reaction based on the Limulus Amebocyte Lysate (LAL) assay, which results in the release of paranitroaniline dye. The dye is measured using a 395 nm filter. The LAL assay detects the Gram-negative bacterial cell wall molecule, endotoxin or lipopolysaccharide (LPS). The more dye released, the greater the concentration of endotoxin in the sample. Sampling, quantitative analysis, and data retrieval require less than 20 minutes. This is significantly faster than standard culture-based methods, which require at least a 24 hour incubation period.Using modified cartridges, we demonstrate the detection of Gram negative bacteria with protein microarray technology. Additionally, we provide data from multiple field tests where both standard and advanced PTS technologies were used. These tests investigate the transfer of target microbial molecules from one surface to another. Collectively, these data demonstrate that the new cartridges expand the number of compounds detected by LOCAD-PTS, while maintaining the rapid, in situ analysis characteristic of the instrument. The unit provides relevant data for verifying sterile sample collection protocols, which are critical for conducting accurate scientific experiments during future missions to the Moon and Mars.

Morris, Heather↗
NASA NTRS2009

The Establishment of a New Friction Stir Welding Process Development Facility at NASA/MSFC

Full-scale weld process development is being performed at MSFC to develop the tools, fixtures, and facilities necessary for Ares I production. Full scale development in-house at MSFC fosters technical acuity within the NASA engineering community, and allows engineers to identify and correct tooling and equipment shortcomings before they become problems on the production floor. Finally, while the new weld process development facility is currently being outfitted in support of Ares I development, it has been established to support all future Constellation Program needs. In particular, both the RWT and VWT were sized with the larger Ares V hardware in mind.

Carter, Robert W.↗
NASA NTRS2009

A3 Subscale Diffuser Test Article Design

This paper gives a detailed description of the design of the A3 Subscale Diffuser Test (SDT) Article Design. The subscale diffuser is a geometrically accurate scale model of the A3 altitude rocket facility. It was designed and built to support the SDT risk mitigation project located at the E3 facility at Stennis Space Center, MS (SSC) supporting the design and construction of the A3 facility at SSC. The subscale test article is outfitted with a large array of instrumentation to support the design verification of the A3 facility. The mechanical design of the subscale diffuser and test instrumentation are described here

Saunders, G. P.↗
NASA NTRS2010

How Mockups, a Key Engineering Tool, Help to Promote Science, Technology, Engineering, and Mathematics Education

The United States ranking among the world in science, technology, engineering, and mathematics (STEM) education is decreasing. To counteract this problem NASA has made it part of its mission to promote STEM education among the nation s youth. Mockups can serve as a great tool when promoting STEM education in America. The Orion Cockpit Working Group has created a new program called Students Shaping America s Next Space Craft (SSANS) to outfit the Medium Fidelity Orion Mockup. SSANS will challenge the students to come up with unique designs to represent the flight design hardware. There are two main types of project packages created by SSANS, those for high school students and those for university students. The high school projects will challenge wood shop, metal shop and pre-engineering classes. The university projects are created mainly for senior design projects and will require the students to perform finite element analysis. These projects will also challenge the undergraduate students in material selection and safety requirements. The SSANS program will help NASA in its mission to promote STEM education, and will help to shape our nations youth into the next generation of STEM leaders.

McDonald, Harry E.↗
NASA NTRS2002

Research Progress and Accomplishments on ISS

The first research payloads reached the International Space Station (ISS) more than two years ago, with research operating continuously since March 2001. Seven research racks are currently on-orbit, with three more arriving soon to expand science capabilities. Through the first five expeditions, 60 unique NASA-managed investigations from 11 nations have been supported, many continuing into later missions. More than 90,000 experiment hours have been completed, and more than 1,000 hours of crew time have been dedicated to research, numbers that grow daily. The multidisciplinary program includes research in life sciences, physical sciences, biotechnology, Earth sciences, technology demonstrations as well as commercial endeavors and educational activities. The Payload Operations and Integration Center monitors the onboard activities around the clock, working with numerous Principal Investigators and Payload Developers at their remote sites. Future years will see expansion of the station with research modules provided by the European Space Agency and Japan, which will be outfitted with additional research racks. The first research payloads arrived at ISS more than two years ago, and continuous science has been ongoing for more than one and a half years. During this time, the research capabilities have been tremendously increased, even as assembly of the overall platform continues. Despite significant challenges along the way, ISS continues to successfully support a large number of investigations in a variety of research disciplines. The results of some of the early investigations are reaching the publication stage. The near future looms with new challenges, but experience to date and dedicated efforts give reason to be optimistic that the challenges will be overcome and that new and greater successes will be added to past ones.

Roe, Lesa B.↗
NASA NTRS2011

Hybrid Composite Cryogenic Tank Structure

A hybrid lightweight composite tank has been created using specially designed materials and manufacturing processes. The tank is produced by using a hybrid structure consisting of at least two reinforced composite material systems. The inner composite layer comprises a distinct fiber and resin matrix suitable for cryogenic use that is a braided-sleeve (and/or a filamentwound layer) aramid fiber preform that is placed on a removable mandrel (outfitted with metallic end fittings) and is infused (vacuum-assisted resin transfer molded) with a polyurethane resin matrix with a high ductility at low temperatures. This inner layer is allowed to cure and is encapsulated with a filamentwound outer composite layer of a distinct fiber resin system. Both inner and outer layer are in intimate contact, and can also be cured at the same time. The outer layer is a material that performs well for low temperature pressure vessels, and it can rely on the inner layer to act as a liner to contain the fluids. The outer layer can be a variety of materials, but the best embodiment may be the use of a continuous tow of carbon fiber (T-1000 carbon, or others), or other high-strength fibers combined with a high ductility epoxy resin matrix, or a polyurethane matrix, which performs well at low temperatures. After curing, the mandrel can be removed from the outer layer. While the hybrid structure is not limited to two particular materials, a preferred version of the tank has been demonstrated on an actual test tank article cycled at high pressures with liquid nitrogen and liquid hydrogen, and the best version is an inner layer of PBO (poly-pphenylenebenzobisoxazole) fibers with a polyurethane matrix and an outer layer of T-1000 carbon with a high elongation epoxy matrix suitable for cryogenic temperatures. A polyurethane matrix has also been used for the outer layer. The construction method is ideal because the fiber and resin of the inner layer has a high strain to failure at cryogenic temperatures, and will not crack or produce leaks. The outer layer serves as more of a high-performance structural unit for the inner layer, and can handle external environments.

DeLay, Thomas↗
NASA NTRS2011

Design of Refractory Metal Heat Pipe Life Test Environment Chamber, Cooling System, and Radio Frequency Heating System

A series of 16 Mo-44.5%Re alloy/sodium heat pipes will be experimentally tested to examine heat pipe aging. To support this evaluation, an environmental test chamber and a number of auxiliary subsystems are required. These subsystems include radio frequency (RF) power supplies/inductive coils, recirculation water coolant loops, and chamber gas conditioning. The heat pipes will be grouped, based on like power and gas mixture requirements, into three clusters of five units each, configured in a pentagonal arrangement. The highest powered heat pipe will be tested separately. Test chamber atmospheric purity is targeted at <0.3 ppb oxygen at an approximate operating pressure of 76 torr (.1.5 psia), maintained by active purification (oxygen level is comparable to a 10(exp -6) torr environment). Treated water will be used in two independent cooling circuits to remove .85 kW. One circuit will service the RF hardware while the other will maintain the heat pipe calorimetry. Initial procedures for the startup and operation of support systems have been identified. Each of these subsystems is outfitted with a variety of instrumentation, integrated with distributed real-time controllers and computers. A local area network provides communication between all devices. This data and control network continuously monitors the health of the test hardware, providing warning indicators followed by automatic shutdown should potentially damaging conditions develop. During hardware construction, a number of checkout tests.many making use of stainless steel prototype heat pipes that are already fabricated.will be required to verify operation.

Martin, J. J.↗
NASA NTRS2002

Integrated Human Test Facilities at NASA and the Role of Human Engineering

Integrated human test facilities are a key component of NASA's Advanced Life Support Program (ALSP). Over the past several years, the ALSP has been developing such facilities to serve as a large-scale advanced life support and habitability test bed capable of supporting long-duration evaluations of integrated bioregenerative life support systems with human test crews. These facilities-targeted for evaluation of hypogravity compatible life support and habitability systems to be developed for use on planetary surfaces-are currently in the development stage at the Johnson Space Center. These major test facilities are comprised of a set of interconnected chambers with a sealed internal environment, which will be outfitted with systems capable of supporting test crews of four individuals for periods exceeding one year. The advanced technology systems to be tested will consist of both biological and physicochemical components and will perform all required crew life support and habitability functions. This presentation provides a description of the proposed test "missions" to be supported by these integrated human test facilities, the overall system architecture of the facilities, the current development status of the facilities, and the role that human design has played in the development of the facilities.

Tri, Terry O.↗
NASA NTRS2004

Mass Properties Measurement in the X-38 Project

This paper details the techniques used in measuring the mass properties for the X-38 family of test vehicles. The X-38 Project was a NASA internal venture in which a series of test vehicles were built in order to develop a Crew Return Vehicle (CRV) for the International Space Station. Three atmospheric test vehicles and one spaceflight vehicle were built to develop the technologies required for a CRV. The three atmospheric test vehicles have undergone flight-testing by a combined team from the NASA Johnson Space Center and the NASA Dryden Flight Research Center. The flight-testing was performed at Edward's Air Force Base in California. The X-38 test vehicles are based on the X-24A, which flew in the '60s and '70s. Scaled Composites, Inc. of Mojave, California, built the airframes and the vehicles were outfitted at the NASA Johnson Space Center in Houston, Texas. Mass properties measurements on the atmospheric test vehicles included weight and balance by the three-point suspension method, four-point suspension method, three load cells on jackstands, and on three in-ground platform scales. Inertia measurements were performed as well in which Ixx, Iyy, Izz, and Ixz were obtained. This paper describes each technique and the relative merits of each. The proposed measurement methods for an X-38 spaceflight test vehicle will also be discussed. This vehicle had different measurement challenges, but integrated vehicle measurements were never conducted. The spaceflight test vehicle was also developed by NASA and was scheduled to fly on the Space Shuttle before the project was cancelled.

Peterson, Wayne L.↗
NASA NTRS2011

An Overview of STS-132 MRM1 Cargo Element Thermal Model Development and Analyses

STS-132 was launched in May 2010 and delivered the Russian Mini Research Module 1 (MRM1) cargo element to the International Space Station as part of the ULF-4 assembly flight. The cargo element consisted of the module outfitted with externally mounted Multi-purpose Laboratory Module (MLM) Airlock, MLM radiator, Portable Work Platform (PWP), and a European Robotic Arm (ERA) spare elbow. Prior to every Shuttle flight, hardware developers are required to determine compatibility of their hardware to thermal environments experienced during the Shuttle mission and once the element is integrated with the ISS. Thermal models are provided to the Shuttle program to determine the impact of the payload on the Orbiter hardware, as well as the ISS program to determine impacts on other ISS payloads in the Orbiter. Historically the Russian International Partner (IP) develops models in formats not compatible with software used by Space Shuttle or ISS programs. This prompted NASA and Lockheed Martin to develop a unique set of thermal models for the MRM1 cargo element. Subsequent ULF-4 mission analyses performed with the models assessed the launch to activation response, identified operational criteria documented in flight rules, and ensured compliance with the mission timeline and no hazards to the crew, orbiter, or ISS. This presentation provides an overview of the work performed, depicts unique approaches in model development, discusses lessons learned, and issue resolution approaches. Though development and analysis efforts spanned over four years and presented various integration challenges it provided an example of successful collaboration with our International Partners.

Perez, Miguel Fernando↗
NASA NTRS2011

Multi-Instance Learning Models for Automated Support of Analysts in Simulated Surveillance Environments

New generations of surveillance drones are being outfitted with numerous high definition cameras. The rapid proliferation of fielded sensors and supporting capacity for processing and displaying data will translate into ever more capable platforms, but with increased capability comes increased complexity and scale that may diminish the usefulness of such platforms to human operators. We investigate methods for alleviating strain on analysts by automatically retrieving content specific to their current task using a machine learning technique known as Multi-Instance Learning (MIL). We use MIL to create a real time model of the analysts' task and subsequently use the model to dynamically retrieve relevant content. This paper presents results from a pilot experiment in which a computer agent is assigned analyst tasks such as identifying caravanning vehicles in a simulated vehicle traffic environment. We compare agent performance between MIL aided trials and unaided trials.

Birisan, Mihnea↗
NASA NTRS2011

A Comparative Analysis of Two Full-Scale MD-500 Helicopter Crash Tests

Two full scale crash tests were conducted on a small MD-500 helicopter at NASA Langley Research Center fs Landing and Impact Research Facility. One of the objectives of this test series was to compare airframe impact response and occupant injury data between a test which outfitted the airframe with an external composite passive energy absorbing honeycomb and a test which had no energy absorbing features. In both tests, the nominal impact velocity conditions were 7.92 m/sec (26 ft/sec) vertical and 12.2 m/sec (40 ft/sec) horizontal, and the test article weighed approximately 1315 kg (2900 lbs). Airframe instrumentation included accelerometers and strain gages. Four Anthropomorphic Test Devices were also onboard; three of which were standard Hybrid II and III, while the fourth was a specialized torso. The test which contained the energy absorbing honeycomb showed vertical impact acceleration loads of approximately 15 g, low risk for occupant injury probability, and minimal airframe damage. These results were contrasted with the test conducted without the energy absorbing honeycomb. The test results showed airframe accelerations of approximately 40 g in the vertical direction, high risk for injury probability in the occupants, and substantial airframe damage.

Littell, Justin D.↗
NASA NTRS2011

Habitat Demonstration Unit-Deep Space Habitat (HDU-DSH) Integration and Preparation for Desert RATS 2011

The Habitat Demonstration Unit, or HDU, is a multi-purpose test bed that allows NASA scientists and engineers to design, develop, and test new living quarters, laboratories, and workspaces for the next generation space mission. Previous testing and integration has occurred during 2010 at the annual Desert Research and Technology Studies (Desert RATS) field testing campaign in the Arizona desert. There the HDU team tests the configuration developed for the fiscal year, or FY configuration. For FY2011, the NASA mission calls for simulating a deep space condition. The HDU-DSH, or Deep Space Habitat, will be configured with new systems and modules that will outfit the test bed with new deep space capabilities. One such addition is the new X-HAB (eXploration Habitat) Inflatable Loft. With any deep space mission there is the need for safe, suitable living quarters. The current HDU configuration does not allow for any living space at all. In fact, Desert RATS 2010 saw the crew sleeping in the Space Exploration Vehicles (SEV) instead of the HDU. The X-HAB Challenge pitted three universities against each other: Oklahoma State University, University of Maryland, and the University of Wisconsin. The winning team will have their design implemented by NASA for field testing at DRATS 2011. This paper will highlight the primary objective of getting the X-HAB field ready which involves the implementation of an elevator/handrail system along with smaller logistical and integration tasks associated with getting the HDU-DSH ready for shipment to DRATS.

Barbeau, Zack↗
NASA NTRS2005

Multilayer Composite Pressure Vessels

A method has been devised to enable the fabrication of lightweight pressure vessels from multilayer composite materials. This method is related to, but not the same as, the method described in gMaking a Metal- Lined Composite-Overwrapped Pressure Vessel h (MFS-31814), NASA Tech Briefs, Vol. 29, No. 3 (March 2005), page 59. The method is flexible in that it poses no major impediment to changes in tank design and is applicable to a wide range of tank sizes. The figure depicts a finished tank fabricated by this method, showing layers added at various stages of the fabrication process. In the first step of the process, a mandrel that defines the size and shape of the interior of the tank is machined from a polyurethane foam or other suitable lightweight tooling material. The mandrel is outfitted with metallic end fittings on a shaft. Each end fitting includes an outer flange that has a small step to accommodate a thin layer of graphite/epoxy or other suitable composite material. The outer surface of the mandrel (but not the fittings) is covered with a suitable release material. The composite material is filament- wound so as to cover the entire surface of the mandrel from the step on one end fitting to the step on the other end fitting. The composite material is then cured in place. The entire workpiece is cut in half in a plane perpendicular to the axis of symmetry at its mid-length point, yielding two composite-material half shells, each containing half of the foam mandrel. The halves of the mandrel are removed from within the composite shells, then the shells are reassembled and bonded together with a belly band of cured composite material. The resulting composite shell becomes a mandrel for the subsequent steps of the fabrication process and remains inside the final tank. The outer surface of the composite shell is covered with a layer of material designed to be impermeable by the pressurized fluid to be contained in the tank. A second step on the outer flange of each end fitting accommodates this layer. Depending on the application, this layer could be, for example, a layer of rubber, a polymer film, or an electrodeposited layer of metal. If the fluid to be contained in the tank is a gas, then the best permeation barrier is electrodeposited metal (typically copper or nickel), which can be effective at a thickness of as little as 0.005 in (.0.13 mm). The electrodeposited metal becomes molecularly bonded to the second step on each metallic end fitting. The permeation-barrier layer is covered with many layers of filament-wound composite material, which could be the same as, or different from, the composite material of the inner shell. Finally, the filament-wound composite material is cured in an ov

DeLay, Tom↗
NASA NTRS2011

The Proposed Use of Unmanned Aerial System Surrogate Research Aircraft for National Airspace System Integration Research

Research is needed to determine what procedures, aircraft sensors and other systems will be required to allow Unmanned Aerial Systems (UAS) to safely operate with manned aircraft in the National Airspace System (NAS). This paper explores the use of Unmanned Aerial System (UAS) Surrogate research aircraft to serve as platforms for UAS systems research, development, and flight testing. These aircraft would be manned with safety pilots and researchers that would allow for flight operations almost anywhere in the NAS without the need for a Federal Aviation Administration (FAA) Certificate of Authorization (COA). With pilot override capability, these UAS Surrogate aircraft would be controlled from ground stations like true UAS s. It would be possible to file and fly these UAS Surrogate aircraft in the NAS with normal traffic and they would be better platforms for real world UAS research and development over existing vehicles flying in restricted ranges or other sterilized airspace. These UAS surrogate aircraft could be outfitted with research systems as required such as computers, state sensors, video recording, data acquisition, data link, telemetry, instrumentation, and Automatic Dependent Surveillance-Broadcast (ADS-B). These surrogate aircraft could also be linked to onboard or ground based simulation facilities to further extend UAS research capabilities. Potential areas for UAS Surrogate research include the development, flight test and evaluation of sensors to aide in the process of air traffic "see-and-avoid". These and other sensors could be evaluated in real-time and compared with onboard human evaluation pilots. This paper examines the feasibility of using UAS Surrogate research aircraft as test platforms for a variety of UAS related research.

Howell, Charles T., III↗
NASA NTRS2011

Characteristics of Subcooled Liquid Methane During Passage Through a Spray-Bar Joule-Thompson Thermodynamic Vent System

NASA s Marshall Space Flight Center (MSFC) conducted liquid methane (LCH4) testing in November 2006 using the multipurpose hydrogen test bed (MHTB) outfitted with a spray-bar thermodynamic vent system (TVS). The basic objective was to identify any unusual or unique thermodynamic characteristics associated with subcooled LCH4 that should be considered in the design of space-based TVSs. Thirteen days of testing were performed with total tank heat loads ranging from 720 W to 420 W at a fill level of approximately 90%. During an updated evaluation of the data, it was noted that as the fluid passed through the Joule Thompson expansion, thermodynamic conditions consistent with the pervasive presence of metastability were indicated. This paper describes the observed thermodynamic conditions that correspond with metastability and effects on TVS performance.

Hastings, L. J.↗
NASA NTRS2011

NASA's Space Launch System Progress Report

Exploration beyond Earth will be an enduring legacy for future generations, confirming America's commitment to explore, learn, and progress. NASA's Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is responsible for designing and developing the first exploration-class rocket since the Apollo Program's Saturn V that sent Americans to the Moon. The SLS offers a flexible design that may be configured for the MultiPurpose Crew Vehicle and associated equipment, or may be outfitted with a payload fairing that will accommodate flagship science instruments and a variety of high-priority experiments. Both options support a national capability that will pay dividends for future generations. Building on legacy systems, facilities, and expertise, the SLS will have an initial lift capability of 70 metric tons (mT) and will be evolvable to 130 mT. While commercial launch vehicle providers service the International Space Station market, this capability will surpass all vehicles, past and present, providing the means to do entirely new missions, such as human exploration of asteroids and Mars. With its superior lift capability, the SLS can expand the interplanetary highway to many possible destinations, conducting revolutionary missions that will change the way we view ourselves, our planet and its place in the cosmos. To perform missions such as these, the SLS will be the largest launch vehicle ever built. It is being designed for safety and affordability - to sustain our journey into the space age. Current plans include launching the first flight, without crew, later this decade, with crewed flights beginning early next decade. Development work now in progress is based on heritage space systems and working knowledge, allowing for a relatively quick start and for maturing the SLS rocket as future technologies become available. Together, NASA and the U.S. aerospace industry are partnering to develop this one-of-a-kind asset. Many of NASA's space centers across the country will provide their unique expertise to the Space Launch System endeavor. Unique infrastructure to be used includes the Michoud Assembly Facility for tank manufacturing, Stennis Space Center for engine testing, and Kennedy Space Center for processing and launch. As this panel will discuss, the SLS team is dedicated to doing things differently-from applying lean oversight/insight models to smartly using legacy hardware and existing facilities. Building on the foundation laid by over 50 years of human and scientific space flight--and on the lessons learned from the Apollo, Space Shuttle, and Constellation Programs-the SLS team has delivered both technical trade studies and business case analyses to ensure that the SLS architecture will be safe, affordable, reliable, and sustainable.

Singer, Joan A.↗