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NASA NTRS2012

Space Launch System Accelerated Booster Development Cycle

With the retirement of the Space Shuttle, NASA is seeking to reinvigorate the national space program and recapture the public s interest in human space exploration by developing missions to the Moon, near-earth asteroids, Lagrange points, Mars, and beyond. The would-be successor to the Space Shuttle, NASA s Constellation Program, planned to take humans back to the Moon by 2020, but due to budgetary constraints was cancelled in 2010 in search of a more "affordable, sustainable, and realistic" concept2. Following a number of studies, the much anticipated Space Launch System (SLS) was unveiled in September of 2011. The SLS core architecture consists of a cryogenic first stage with five Space Shuttle Main Engines (SSMEs), and a cryogenic second stage using a new J-2X engine3. The baseline configuration employs two 5-segment solid rocket boosters to achieve a 70 metric ton payload capability, but a new, more capable booster system will be required to attain the goal of 130 metric tons to orbit. To this end, NASA s Marshall Space Flight Center recently released a NASA Research Announcement (NRA) entitled "Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction." The increased emphasis on affordability is evident in the language used in the NRA, which is focused on risk reduction "leading to an affordable Advanced Booster that meets the evolved capabilities of SLS" and "enabling competition" to "enhance SLS affordability. The purpose of the work presented in this paper is to perform an independent assessment of the elements that make up an affordable and realistic path forward for the SLS booster system, utilizing advanced design methods and technology evaluation techniques. The goal is to identify elements that will enable a more sustainable development program by exploring the trade space of heavy lift booster systems and focusing on affordability, operability, and reliability at the system and subsystem levels5. For this study, affordability is defined as lifecycle cost, which includes design, development, test, and engineering (DDT&E), production and operational costs (P&O). For this study, the system objectives include reducing DDT&E schedule by a factor of three, showing 99.9% reliability, flying up to four times per year, serving both crew and cargo missions, and evolving to a lift capability of 130 metric tons.3 After identifying gaps in the current system s capabilities, this study seeks to identify non-traditional and innovative technologies and processes that may improve performance in these areas and assess their impacts on booster system development. The DDT&E phase may be improved by incorporating incremental development testing and integrated demonstrations to mitigate risk. To further reduce DDT&E, this study will also consider how aspects of the booster system may have commonality with other users, such as the Department of Defense, commercial applications, or international partners; by sharing some of the risk and investment, the overall development cost may be reduced. Consideration is not limited to solid and liquid rocket boosters. A set of functional performance characteristics, such as engine thrust, specific impulse (Isp), mixture ratio, and throttle range are identified and their impacts on the system are evaluated. This study also identifies how such characteristics affect overall life cycle cost, including DDT&E and fixed and variable P&O.

Arockiam, Nicole↗
NASA NTRS2015

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS; and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. For NASA's SLS ABEDRR procurement, Dynetics and AR formed a team to offer a series of full-scale risk mitigation hardware demonstrations for an affordable booster approach that meets the evolved capabilities of the SLS. To establish a basis for the risk reduction activities, the Dynetics Team developed a booster design that takes advantage of the flight-proven Apollo-Saturn F-1. Using NASA's vehicle assumptions for the SLS Block 2, a two-engine, F-1-based booster design delivers 150 mT (331 klbm) payload to LEO, 20 mT (44 klbm) above NASA's requirements. This enables a low-cost, robust approach to structural design. During the ABEDRR effort, the Dynetics Team has modified proven Apollo-Saturn components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically produced Atlas V engine that could also potentially satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete critical design review this fall and begin testing in 2017. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements. This paper will discuss the ABEDRR engine task and structures task achievements to date and the remaining effort through the end of the contract.

Crocker, Andrew M.↗
NASA NTRS2010

Fission Surface Power Technology Development Status

Power is a critical consideration in planning exploration of the surfaces of the Moon, Mars, and beyond. Nuclear power is an important option, especially for locations in the solar system where sunlight is limited in availability or intensity. NASA is maintaining the option for fission surface power for the Moon and Mars by developing and demonstrating technology for an affordable fission surface power system. Because affordability drove the determination of the system concept that this technology will make possible, low development and recurring costs result, while required safety standards are maintained. However, an affordable approach to fission surface power also provides the benefits of simplicity, robustness, and conservatism in design. This paper will illuminate the multiplicity of benefits to an affordable approach to fission surface power, and will describe how the foundation for these benefits is being developed and demonstrated in the Exploration Technology Development Program s Fission Surface Power Project.

Palac, Donald T.↗
NASA NTRS2010

Advanced Space Fission Propulsion Systems

Fission has been considered for in-space propulsion since the 1940s. Nuclear Thermal Propulsion (NTP) systems underwent extensive development from 1955-1973, completing 20 full power ground tests and achieving specific impulses nearly twice that of the best chemical propulsion systems. Space fission power systems (which may eventually enable Nuclear Electric Propulsion) have been flown in space by both the United States and the Former Soviet Union. Fission is the most developed and understood of the nuclear propulsion options (e.g. fission, fusion, antimatter, etc.), and fission has enjoyed tremendous terrestrial success for nearly 7 decades. Current space nuclear research and technology efforts are focused on devising and developing first generation systems that are safe, reliable and affordable. For propulsion, the focus is on nuclear thermal rockets that build on technologies and systems developed and tested under the Rover/NERVA and related programs from the Apollo era. NTP Affordability is achieved through use of previously developed fuels and materials, modern analytical techniques and test strategies, and development of a small engine for ground and flight technology demonstration. Initial NTP systems will be capable of achieving an Isp of ~900 s at a relatively high thrust-to-weight ratio. The development and use of first generation space fission power and propulsion systems will provide new, game changing capabilities for NASA. In addition, development and use of these systems will provide the foundation for developing extremely advanced power and propulsion systems capable of routinely and affordably accessing any point in the solar system. The energy density of fissile fuel (8 x 10(exp 13) Joules/kg) is more than adequate for enabling extensive exploration and utilization of the solar system. For space fission propulsion systems, the key is converting the virtually unlimited energy of fission into thrust at the desired specific impulse and thrust-to-weight ratio. This presentation will discuss potential space fission propulsion options ranging from first generation systems to highly advanced systems. Ongoing research that shows promise for enabling second generation NTP systems with Isp greater than 1000 s will be discussed, as will the potential for liquid, gas, or plasma core systems. Space fission propulsion systems could also be used in conjunction with simple (water-based) propellant depots to enable routine, affordable missions to various destinations (e.g. moon, Mars, asteroids) once in-space infrastructure is sufficiently developed. As fuel and material technologies advance, very high performance Nuclear Electric Propulsion (NEP) systems may also become viable. These systems could enable sophisticated science missions, highly efficient cargo delivery, and human missions to numerous destinations. Commonalities between NTP, fission power systems, and NEP will be discussed.

Houts, Michael G.↗
NASA NTRS2004

Improved Phase-Mask Fabrication of Fiber Bragg Gratings

An improved method of fabrication of Bragg gratings in optical fibers combines the best features of two prior methods: one that involves the use of a phase mask and one that involves interference between the two coherent laser beams. The improved method affords flexibility for tailoring Bragg wavelengths and bandwidths over wide ranges. A Bragg grating in an optical fiber is a periodic longitudinal variation in the index of refraction of the fiber core. The spatial period (Bragg wavelength) is chosen to obtain enhanced reflection of light of a given wavelength that would otherwise propagate relatively unimpeded along the core. Optionally, the spatial period of the index modulation can be made to vary gradually along the grating (such a grating is said to be chirped ) in order to obtain enhanced reflection across a wavelength band, the width of which is determined by the difference between the maximum and minimum Bragg wavelengths. In the present method as in both prior methods, a Bragg grating is formed by exposing an optical fiber to an ultraviolet-light interference field. The Bragg grating coincides with the pattern of exposure of the fiber core to ultraviolet light; in other words, the Bragg grating coincides with the interference fringes. Hence, the problem of tailoring the Bragg wavelength and bandwidth is largely one of tailoring the interference pattern and the placement of the fiber in the interference pattern. In the prior two-beam interferometric method, a single laser beam is split into two beams, which are subsequently recombined to produce an interference pattern at the location of an optical fiber. In the prior phase-mask method, a phase mask is used to diffract a laser beam mainly into two first orders, the interference between which creates the pattern to which an optical fiber is exposed. The prior two-beam interferometric method offers the advantage that the period of the interference pattern can be adjusted to produce gratings over a wide range of Bragg wavelengths, but offers the disadvantage that success depends on precise alignment and high mechanical stability. The prior phase-mask method affords the advantages of compactness of equipment and relative insensitivity to both misalignment and vibration, but does not afford adjustability of the Bragg wavelength. The present method affords both the flexibility of the prior two-beam interferometric method and the compactness and stability of the prior phase-mask method. In this method (see figure), a laser beam propagating along the x axis is normally incident on a phase mask that lies in the (y,z) plane. The phase of light propagating through the mask is modulated with a spatial periodicity, p, along the y axis chosen to diffract the laser light primarily to first order at the angle . (The zero-order laser light propagating along the x axis can be used for alignment and thereafter suppressed during exposure of the fiber.) The diffracted light passes through a concave cylindrical lens, which converts the flat diffracted wave fronts to cylindrical ones, as though the light emanated from a line source. Then two parallel flat mirrors recombine the diffracted beams to form an interference field equivalent to that of two coherent line sources at positions A and B (virtual sources). The interference pattern is a known function of the parameters of the apparatus and of position (x,y) in the interference field. Hence, the tilt, wavelength, and chirp of the Bragg grating can be chosen through suitable adjustments of the apparatus and/or of the position and orientation of the optical fiber. In particular, the Bragg wavelength can be adjusted by moving the fiber along the x axis, and the bandwidth can be modified over a wide range by changing the fiber tilt angle or by moving the phase mask and/or the fiber. Alignment is easy because the zero-order beam defines the x axis. The interference is relatively stable and insensitive to the mechanical vibration because of the gh symmetry and compactness of the apparatus, the fixed positions of the mirrors and lens, and the consequent fixed positions of the two virtual line sources, which are independent of the translations of the phase mask and the laser relative to the lens.

Grant, Joseph↗
NASA NTRS2014

The Nuclear Cryogenic Propulsion Stage

Nuclear Thermal Propulsion (NTP) development efforts in the United States have demonstrated the technical viability and performance potential of NTP systems. For example, Project Rover (1955 - 1973) completed 22 high power rocket reactor tests. Peak performances included operating at an average hydrogen exhaust temperature of 2550 K and a peak fuel power density of 5200 MW/m3 (Pewee test), operating at a thrust of 930 kN (Phoebus-2A test), and operating for 62.7 minutes in a single burn (NRX-A6 test). Results from Project Rover indicated that an NTP system with a high thrust-to-weight ratio and a specific impulse greater than 900 s would be feasible. Excellent results were also obtained by the former Soviet Union. Although historical programs had promising results, many factors would affect the development of a 21st century nuclear thermal rocket (NTR). Test facilities built in the US during Project Rover no longer exist. However, advances in analytical techniques, the ability to utilize or adapt existing facilities and infrastructure, and the ability to develop a limited number of new test facilities may enable affordable development, qualification, and utilization of a Nuclear Cryogenic Propulsion Stage (NCPS). Bead-loaded graphite fuel was utilized throughout the Rover/NERVA program, and coated graphite composite fuel (tested in the Nuclear Furnace) and cermet fuel both show potential for even higher performance than that demonstrated in the Rover/NERVA engine tests.. NASA's NCPS project was initiated in October, 2011, with the goal of assessing the affordability and viability of an NCPS. FY 2014 activities are focused on fabrication and test (non-nuclear) of both coated graphite composite fuel elements and cermet fuel elements. Additional activities include developing a pre-conceptual design of the NCPS stage and evaluating affordable strategies for NCPS development, qualification, and utilization. NCPS stage designs are focused on supporting human Mars missions. The NCPS is being designed to readily integrate with the Space Launch System (SLS). A wide range of strategies for enabling affordable NCPS development, qualification, and utilization should be considered. These include multiple test and demonstration strategies (both ground and in-space), multiple potential test sites, and multiple engine designs. Two potential NCPS fuels are currently under consideration - coated graphite composite fuel and tungsten cermet fuel. During 2014 a representative, partial length (approximately 16") coated graphite composite fuel element with prototypic depleted uranium loading is being fabricated at Oak Ridge National Laboratory (ORNL). In addition, a representative, partial length (approximately 16") cermet fuel element with prototypic depleted uranium loading is being fabricated at Marshall Space Flight Center (MSFC). During the development process small samples (approximately 3" length) will be tested in the Compact Fuel Element Environmental Tester (CFEET) at high temperature (approximately 2800 K) in a hydrogen environment to help ensure that basic fuel design and manufacturing process are adequate and have been performed correctly. Once designs and processes have been developed, longer fuel element segments will be fabricated and tested in the Nuclear Thermal Rocket Element Environmental Simulator (NTREE) at high temperature (approximately 2800 K) and in flowing hydrogen.

Houts, Michael G.↗
NASA NTRS2015

NASA's Nuclear Thermal Propulsion Project

Space fission power systems can provide a power rich environment anywhere in the solar system, independent of available sunlight. Space fission propulsion offers the potential for enabling rapid, affordable access to any point in the solar system. One type of space fission propulsion is Nuclear Thermal Propulsion (NTP). NTP systems operate by using a fission reactor to heat hydrogen to very high temperature (>2500 K) and expanding the hot hydrogen through a supersonic nozzle. First generation NTP systems are designed to have an Isp of approximately 900 s. The high Isp of NTP enables rapid crew transfer to destinations such as Mars, and can also help reduce mission cost, improve logistics (fewer launches), and provide other benefits. However, for NTP systems to be utilized they must be affordable and viable to develop. NASA's Advanced Exploration Systems (AES) NTP project is a technology development project that will help assess the affordability and viability of NTP. Early work has included fabrication of representative graphite composite fuel element segments, coating of representative graphite composite fuel element segments, fabrication of representative cermet fuel element segments, and testing of fuel element segments in the Compact Fuel Element Environmental Tester (CFEET). Near-term activities will include testing approximately 16" fuel element segments in the Nuclear Thermal Rocket Element Environmental Simulator (NTREES), and ongoing research into improving fuel microstructure and coatings. In addition to recapturing fuels technology, affordable development, qualification, and utilization strategies must be devised. Options such as using low-enriched uranium (LEU) instead of highly-enriched uranium (HEU) are being assessed, although that option requires development of a key technology before it can be applied to NTP in the thrust range of interest. Ground test facilities will be required, especially if NTP is to be used in conjunction with high value or crewed missions. There are potential options for either modifying existing facilities or constructing new ground test facilities. At least three potential options exist for reducing (or eliminating) the release of radioactivity into the environment during ground testing. These include fully containing the NTP exhaust during the ground test, scrubbing the exhaust, or utilizing an existing borehole at the Nevada National Security Site (NNSS) to filter the exhaust. Finally, the project is considering the potential for an early flight demonstration of an engine very similar to one that could be used to support human Mars or other ambitious missions. The flight demonstration could be an important step towards the eventual utilization of NTP.

Houts, Michael↗
NASA NTRS2017

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..

Crocker, Andrew M.↗
NASA NTRS2018

Potential Advantages of Conducting Short Duration Visits to the Martian Surface

Recent NASA concepts for human missions to Mars, including the Evolvable Mars Campaign and Design Reference Architecture 5.0, have focused on the conduct of missions with long duration stays on the Martian surface. The decision to focus on long duration missions (typically to a single site) is driven by a desire to increase the perceived sustainability of the human Mars campaign, predicated on the assumption that sustainability is best achieved by maximizing the level of activity on the surface, providing for continuous growth in operations, and promoting pioneering of Mars. However, executing a series of long duration missions to a single site is not the only option for human exploration of Mars that has been proposed. Other architectures have been evaluated that focus on missions with short duration surface stays, with each mission visiting a separate site on the surface. This type of architecture is less efficient in that elements are not typically reused from one mission to the next but requires a far less complex surface architecture. There are potentially valid arguments to be made that a short duration, multiple site approach could result in different types of advantages when compared to the long duration, single site approach to Mars exploration, particularly for initial human missions to Mars. These arguments revolve around four areas: Achieved Value, Risk Mitigation, Developmental Affordability, and Operational Affordability & Flexibility. The question of Achieved Value relates to the prioritization of goals for Martian exploration. As discussed, goals related to pioneering and expanding human presence are often referenced as justifications for the long duration approach. However, there are other competing goals, including science and exploration. While there is not a clear consensus among planetary scientists, many have argued that the value of being able to visit multiple sites could outweigh the value of continually visiting a single site. Risk Mitigation is a major concern for initial human missions to Mars. There are a number of hazards related to operating on the Martian surface that are not well characterized. It may be desirable to conduct a series of short duration missions to better understand the nature of these risks prior to committing to a long duration mission. Developmental Affordability relates to the ability of NASA and its partners to develop and deploy the proposed architecture. Any human missions to Mars will be among the most complex endeavors ever undertaken. The capabilities that must be developed to enable any human Mars missions are extremely challenging. The total design, development, test, and evaluation (DDT&E) budget required to develop just the essential capabilities alone will be substantial. If additional surface capabilities are required to support long duration surface stays, the development effort could be unaffordable. Operational Affordability & Flexibility relates to the continued costs to execute the Mars campaign. Long duration missions, even with some amount of in-situ resource utilization, require a significant level of resupply for every mission. This requires additional launches and in-space transportation assets, increasing the operational complexity and total operational cost. This paper will explore each of the four potential advantages of short duration missions in detail. The authors will present comparisons between proposed long duration and short duration architectures through an evaluation of relevant performance, cost, and risk metrics.

Stromgren, Chel↗
NASA NTRS1981

Technology - The path to the next 50 years

The paper stresses the importance of committing time and resources to space technology based on the premise that an accurate appraisal of the impact of technology and other influences on the present state of aviation will facilitate the planning of space technology. The paper presents the technological advances in aviation since 1903 by dividing the era of aviation into four distinct segments and, by analogy, distinct phases are also seen in the evolution of space flight. One factor seen as limiting advances in space is cost. Processes in space must now be shown to be affordable; a demonstration of technological feasibility is no longer sufficient. For this reason, technology must focus on ensuring the affordability and utility of space processes. A commitment to making space affordable will yield the tools necessary to embark on future space ventures.

Williams, D. P.↗
NASA NTRS1991

Lessons learned for composite structures

Lessons learned for composite structures are presented in three technology areas: materials, manufacturing, and design. In addition, future challenges for composite structures are presented. Composite materials have long gestation periods from the developmental stage to fully matured production status. Many examples exist of unsuccessful attempts to accelerate this gestation period. Experience has shown that technology transition of a new material system to fully matured production status is time consuming, involves risk, is expensive and should not be undertaken lightly. The future challenges for composite materials require an intensification of the science based approach to material development, extension of the vendor/customer interaction process to include all engineering disciplines of the end user, reduced material costs because they are a significant factor in overall part cost, and improved batch-to-batch pre-preg physical property control. Historical manufacturing lessons learned are presented using current in-service production structure as examples. Most producibility problems for these structures can be traced to their sequential engineering design. This caused an excessive emphasis on design-to-weight and schedule at the expense of design-to-cost. This resulted in expensive performance originated designs, which required costly tooling and led to non-producible parts. Historically these problems have been allowed to persist throughout the production run. The current/future approach for the production of affordable composite structures mandates concurrent engineering design where equal emphasis is placed on product and process design. Design for simplified assembly is also emphasized, since assembly costs account for a major portion of total airframe costs. The future challenge for composite manufacturing is, therefore, to utilize concurrent engineering in conjunction with automated manufacturing techniques to build affordable composite structures. Composite design experience has shown that significant weight savings have been achieved, outstanding fatigue and corrosion resistance have been demonstrated, and in-service performance has been very successful. Currently no structural design show stoppers exist for composite structures. A major lesson learned is that the full scale static test is the key test for composites, since it is the primary structural 'hot spot' indicator. The major durability issue is supportability of thin skinned structure. Impact damage has been identified as the most significant issue for the damage tolerance control of composite structures. However, delaminations induced during assembly operations have demonstrated a significant nuisance value. The future challenges for composite structures are threefold. Firstly, composite airframe weight fraction should increase to 60 percent. At the same time, the cost of composite structures must be reduced by 50 percent to attain the goal of affordability. To support these challenges it is essential to develop lower cost materials and processes.

Whitehead, R. S.↗
NASA NTRS1999

New RTM/RI Resins for the HSCT

In the first portion of this work, 1,2,3,3,4,4-hexafluoro-1,2-bis[4-(dimethylhydroxysilyl)phenoxy]cyclobutane and 1,2,3,3,4,4-hexafluoro-1,2-bis[3-(dimethylhydroxysilyl)phenoxy]cyclobutane were prepared and homopolymerized to afford polymers with excellent thermal stability and Tgs of 27 C and -12 C, respectively. Despite the moderately high wt% of fluorin in the polymer structure (23.8%), these polymers had poor fuel resistance. In fact, swelling measurements indicate that these polymers had apparent solubility parameters of about 18.2 J (exp 1/2) m (exp -3/2) (toluene). Copolymerization of the disilanol monomers with fluorosilicone monomers afforded copolymers containing 20-30 wt% of the perfluorocyclobutane-containing structure displayed adequate fuel resistance, enhanced thermal stability, and a Tg low enough to meet the requirements of a High Speed Civil Transport (HSCT) fuel tank sealant. In the second part of this work, trifluorovinylether-terminated oligomers were prepared and polymerized via cyclodimerization. Initially, an alpha, omega-silanol-terminated fluorosilicone was endcapped with trifluorovinylether end groups via a two-step synthetic sequence. The oligomer was thermally cyclodimerized to a polymer that displayed thermal stability similar to that of a fluorosilicone homopolymer. Second, 1,3-bis[4-trifluorovinyl(oxy)phenyl]-1,3-(3,3,3-trifluoropropyl)dimethyldisiloxane and 1,3-bis{3-trifluorovinyl(oxy)phenyl]-1,3-(3,3,3-trifluoropropyl)dimethyldisiloxane were prepared and cyclodimerized to afford polymers that contained pendant trifluoropropyl groups. The pendant trifluoropropyl groups did enhance solvent resistance in aliphatic hydrocarbon solvents, however, no improvement was observed in aromatic hydrocarbon solvents. These polymers also displayed excellent thermal stability. In the last part of this work, a series of monomers was prepared by the DCC-promoted esterification of 4-[trifluorovinyl(oxy)benzoic acid with alpha, omega-functionalized hydrogenated and partially fluorinated alcohols. The monomers were cyclodimerized to the corresponding polymers. The polymers that did not contain beta hydrogens displayed significantly higher thermal stability than the fully hydrogenated polymers. A commercially-available alpha,omega-hydroxy-terminated perfluoropolyether was then functionalized with 4-[trifluorovinyl(oxy)benzoylchloride. An attempt was made to polymerize the resulting oligomer via the cyclodimerization of the terminal trifluorovinylether moieties. Although the viscosity of the oligomer increased significantly during polymerization, Gel Permeation Chromatography (GPC) analysis revealed that the Tetrahydrofuran (THF) soluble portion of the polymer did not have high molecular weight.

Harris, Frank W.↗
NASA NTRS2000

First Generation Least Expensive Approach to Fission (FiGLEAF) Testing Results

Successful development of space fission systems will require an extensive program of affordable and realistic testing. In addition to tests related to design/development of the fission system, realistic testing of the actual flight unit must also be performed. Testing can be divided into two categories, non-nuclear tests and nuclear tests. Full power nuclear tests of space fission systems are expensive, time consuming, and of limited use, even in the best of programmatic environments. If the system is designed to operate within established radiation damage and fuel burn up limits while simultaneously being designed to allow close simulation of heat from fission using resistance heaters, high confidence in fission system performance and lifetime can be attained through a series of non-nuclear tests. Non-nuclear tests are affordable and timely, and the cause of component and system failures can be quickly and accurately identified. MSFC is leading a Safe Affordable Fission Engine (SAFE) test series whose ultimate goal is the demonstration of a 300 kW flight configuration system using non-nuclear testing. This test series is carried out in collaboration with other NASA centers, other government agencies, industry, and universities. The paper describes the SAFE test series, which includes test article descriptions, test results and conclusions, and future test plans.

VanDyke, Melissa↗
NASA NTRS2001

Space Fission Propulsion Testing and Development Progress

Successful development of space fission systems will require an extensive program of affordable and realistic testing. In addition to tests related to design/development of the fission system, realistic testing of the actual flight unit must also be performed. Testing can be divided into two categories, non-nuclear tests and nuclear tests. Full power nuclear tests of space fission systems we expensive, time consuming, and of limited use, even in the best of programmatic environments. If the system is designed to operate within established radiation damage and fuel burn up limits while simultaneously being designed to allow close simulation of heat from fission using resistance heaters, high confidence in fission system performance and lifetime can be attained through a series of non-nuclear tests. Non-nuclear tests are affordable and timely, and the cause of component and system failures can be quickly and accurately identified. MSFC is leading a Safe Affordable Fission Engine (SAFE) test series whose ultimate goal is the demonstration of a 300 kW flight configuration system using non-nuclear testing. This test series is carried out in collaboration with other NASA centers, other government agencies, industry, and universities. If SAFE-related nuclear tests are desired they will have a high probability of success and can be performed at existing nuclear facilities. The paper describes the SAFE non-nuclear test series, which includes test article descriptions, test results and conclusions, and future test plans.

VanDyke, Melissa↗
NASA NTRS2002

Development of Advanced Life Cycle Costing Methods for Technology Benefit/Cost/Risk Assessment

The overall objective of this three-year grant is to provide NASA Langley's System Analysis Branch with improved affordability tools and methods based on probabilistic cost assessment techniques. In order to accomplish this objective, the Aerospace Systems Design Laboratory (ASDL) needs to pursue more detailed affordability, technology impact, and risk prediction methods and to demonstrate them on variety of advanced commercial transports. The affordability assessment, which is a cornerstone of ASDL methods, relies on the Aircraft Life Cycle Cost Analysis (ALCCA) program originally developed by NASA Ames Research Center and enhanced by ASDL. This grant proposed to improve ALCCA in support of the project objective by updating the research, design, test, and evaluation cost module, as well as the engine development cost module. Investigations into enhancements to ALCCA include improved engine development cost, process based costing, supportability cost, and system reliability with airline loss of revenue for system downtime. A probabilistic, stand-alone version of ALCCA/FLOPS will also be developed under this grant in order to capture the uncertainty involved in technology assessments. FLOPS (FLight Optimization System program) is an aircraft synthesis and sizing code developed by NASA Langley Research Center. This probabilistic version of the coupled program will be used within a Technology Impact Forecasting (TIF) method to determine what types of technologies would have to be infused in a system in order to meet customer requirements. A probabilistic analysis of the CER's (cost estimating relationships) within ALCCA will also be carried out under this contract in order to gain some insight as to the most influential costs and the impact that code fidelity could have on future RDS (Robust Design Simulation) studies.

Yackovetsky, Robert↗
NASA NTRS2001

Phase 1 Space Fission Propulsion System Design Considerations

Fission technology can enable rapid, affordable access to any point in the solar system. If fission propulsion systems are to be developed to their full potential; however, near-term customers must be identified and initial fission systems successfully developed, launched, and operated. Studies conducted in fiscal year 2001 (IISTP, 2001) show that fission electric propulsion (FEP) systems operating at 80 kWe or above could enhance or enable numerous robotic outer solar system missions of interest. At these power levels it is possible to develop safe, affordable systems that meet mission performance requirements. In selecting the system design to pursue, seven evaluation criteria were identified: safety, reliability, testability, specific mass, cost, schedule, and programmatic risk. A top-level comparison of three potential concepts was performed: an SP-100 based pumped liquid lithium system, a direct gas cooled system, and a heatpipe cooled system. For power levels up to at least 500 kWt (enabling electric power levels of 125-175 kWe, given 25-35% power conversion efficiency) the heatpipe system has advantages related to several criteria and is competitive with respect to all. Hardware-based research and development has further increased confidence in the heatpipe approach. Successful development and utilization of a "Phase 1" fission electric propulsion system will enable advanced Phase 2 and Phase 3 systems capable of providing rapid, affordable access to any point in the solar system.

Houts, Mike↗
NASA NTRS2002

Phase 1 Space Fission Propulsion Energy Source Design

Fission technology can enable rapid, affordable access to any point in the solar system. If fission propulsion systems are to be developed to their full potential; however, near-term customers must be identified and initial fission systems successfully developed, launched, and operated. Studies conducted in fiscal year 2001 (IISTP, 2001) show that fission electric propulsion (FEP) systems with a specific mass at or below 50 kg/kWjet could enhance or enable numerous robotic outer solar system missions of interest. At the required specific mass, it is possible to develop safe, affordable systems that meet mission requirements. To help select the system design to pursue, eight evaluation criteria were identified: system integration, safety, reliability, testability, specific mass, cost, schedule, and programmatic risk. A top-level comparison of four potential concepts was performed: a Testable, Passive, Redundant Reactor (TPRR), a Testable Multi-Cell In-Core Thermionic Reactor (TMCT), a Direct Gas Cooled Reactor (DGCR), and a Pumped Liquid Metal Reactor.(PLMR). Development of any of the four systems appears feasible. However, for power levels up to at least 500 kWt (enabling electric power levels of 125-175 kWe, given 25-35% power conversion efficiency) the TPRR has advantages related to several criteria and is competitive with respect to all. Hardware-based research and development has further increased confidence in the TPRR approach. Successful development and utilization of a "Phase I" fission electric propulsion system will enable advanced Phase 2 and Phase 3 systems capable of providing rapid, affordable access to any point in the solar system.

Houts, Mike↗
NASA NTRS2005

A Robust, Low-Cost Virtual Archive for Science Data

Despite their expense tape silos are still often the only affordable option for petabytescale science data archives, particularly when other factors such as data reliability, floor space, power and cooling load are accounted for. However, the complexity, management software, hardware reliability and access latency of tape silos make online data storage ever more attractive. Drastic reductions in low-cost mass-market PC disk drivers help to make this more affordable (approx. 1$/GB), but are challenging to scale to the petabyte range and of questionable reliability for archival use, On the other hand, if much of the science archive could be "virtualized", i.e., produced on demand when requested by users, we would need store only a fraction of the data online, perhaps bringing an online-only system into in affordable range. Radiance data from the satellite-borne Moderate Resolution Imaging Spectroradiometer (MODIS) instrument provides a good opportunity for such a virtual archive: the raw data amount to 140 GB/day, but these are small relative to the 550 GB/day making up the radiance products. These data are routinely processed as inputs for geophysical parameter products and then archived on tape at the Goddard Earth Sciences Distributed Active Archive (GES DAAC) for distributing to users. Virtualizing them would be an immediate and signifcant reduction in the amount of data being stored in the tape archives and provide more customizable products. A prototype of such a virtual archive is being developed to prove the concept and develop ways of incorporating the robustness that a science data archive requires.

Lynnes, Christopher↗