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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2019

Orion Heat Shield Manufacturing Producibility Improvements for the EM-1 Flight Test Program

This paper describes how the Orion program is incorporating improvements in the heat shield design and manufacturing processes reducing programmatic risk and ensuring crew safety in support of NASA’s Exploration Missions. The Orion program successfully completed the EFT-1 flight test in 2014 and is currently developing the EM-1 spacecraft to meet the test objectives of an orbital mission to the moon and return to earth in 2019. Lessons learned from the EFT-1 manufacturing and flight test experience are being incorporated into a wide variety of vehicle systems and manufacturing processes to reduce risk to the Orion missions and flight crew. A critical contributor to crew safety is the heat shield that protects the crew capsule during re-entry through the earth’s atmosphere for return from deep space. The first flight test vehicle, EFT-1, was manufactured and tested in the Neil Armstrong Operations and Checkout (O&C) facility at KSC to demonstrate early risk reduction including the functionality of the Thermal Protection Systems (TPS) for capsule safe return to earth. The approach for the EFT-1 heat shield utilized a low risk approach using Apollo heritage design and manufacturing processes using an Avcoat TPS ablator with a honeycomb substrate to provide a one piece heat shield to meet the mission re-entry heating environments. The manufacturing processes used honeycomb cell injection guns which were redeveloped from the Apollo Lunar Program processes to build the EFT-1 heat shield. The completed heat shield was transported across the country by aircraft to the O&C at KSC for installation onto the capsule. The EFT-1 heat shield successfully performed its mission and experienced ~80% of the re-entry velocity (50% heating rate) for a lunar return for an Exploration Mission. The second flight test vehicle is the EM-1 mission which will have additional flight systems installed to fly to the moon and return. Heat shield design and producibility improvements have been incorporated in the EM-1 vehicle to meet deep space mission and programmatic requirements. The design continues to use the Avcoat material, but in a “block” configuration to enable improvements in the application processes as well as additional improvements in the carrier structure design and manufacturing operations. Incorporating flight test results and producibility improvements from EFT-1 for the heat shield system design and processes have improved the thermal protection capability, improved the producibility, and cost for EM-1 flight test.

Producibility↗
NASA NTRS1984

Development of a bipropellant propulsion module for the Galileo spacecraft

The bipropellant engine retropropulsion module (RPM) of the Jupiter-exploration Galileo spacecraft provides attitude control, trajectory correction, a deep space velocity increment, a spacecraft deflection maneuver for an entry capsule, a retromaneuver for Jupiter approach, and a 'perijove raise' maneuver for the Jovian system tour of the spacecraft. Attention is given to the design features and performance capabilities of the RPM, which uses a set of 12 10-N thrusters in conjunction with a 400-N engine. Tanks contain 935 kg of propellant to satisfy mission requirements.

Hagenest, W.↗
NASA NTRS1988

Alternate transportation system

Three missions have been identified by NASA for a Space Shuttle-supplementing Alternate Transportation System (ATS) encompassing combinations of booster vehicles, crew modules, and service modules: (1) to achieve manned access to orbit for Space Station crew rotation every 90 days, (2) the lofting of a logistics module resupplying the Space Station every 180 days, and (3) the simultaneous launch of both crews and logistics to the Space Station. A reentry glider is considered, in conjunction with the Space Shuttle's unmanned cargo version and the Apollo manned capsule, as an important ATS element. The Titan IV/NUS is used as a booster.

Zertuche, Tony↗
NASA NTRS2000

Microgravity Research Results and Experiences from the NASA Mir Space Station Program

The Microgravity Research Program Office (MRPO) participated aggressively in Phase I of the International Space Station Program using the Russian Mir Space Station. The Mir Station offered an otherwise unavailable opportunity to explore the advantages and challenges to long duration microgravity space research. Payloads with both NASA and commercial backing were included as well as cooperative research with the Canadian Space Agency (CSA). From this experience, much was learned about dealing with long duration on orbit science utilization and developing new working relationships with our Russian partner to promote efficient planning, operations, and integration to solve complexities associated with a multiple partner program. Microgravity participation in the NASA Mir Program began with the first joint NASA Mir flight to the Mir Space Station. The earliest participation setup acceleration measurement capabilities that were used throughout the Program. Research, conducted by all Microgravity science disciplines, continued on each subsequent increment for the entire three-year duration of the Program. The Phase I Program included the Microgravity participation of over 30 Fluids, Combustion, Materials, and Biotechnology Sciences and numerous commercially sponsored research payloads. In addition to the research gained from Microgravity investigations, long duration operation of facility hardware was tested. Microgravity facilities operated on Mir included the Space Acceleration Measurement System (SAMS), the Microgravity Glovebox (MGBX), the Biotechnology System (BTS) and the Canadian Space Agency sponsored Microgravity Isolation Mount (MIM). The Russian OPTIZONE Furnace was also incorporated into our material science research. All of these efforts yielded significant and useful scientific research data. This paper focuses on the microgravity research conducted onboard the Mir space station. It includes the Program preparation and planning necessary to support this type of cross increment research experience; the payloads which were flown; and summaries of significant microgravity science findings. Most importantly this paper highlights the various disciplines of microgravity research conducted during the International Space Station, Phase 1 Program onboard the Mir Station. A capsulation of significant research and the applicability of our findings are provided. In addition, a brief discussion of how future microgravity science gathering capabilities, hardware development and payload operations techniques have enhanced our ability to conduct long duration microgravity research.

Schagheck, R. A.↗
NASA NTRS2012

Antenna Measurements: Test & Analysis of the Radiated Emissions from the NASA/Orion Spacecraft - Parachute System Simulator

For future NASA Manned Space Exploration of the Moon and Mars, a blunt body capsule, called the Orion Crew Exploration Vehicle (CEV), composed of a Crew Module (CM) and a Service Module (SM), with a parachute decent assembly is planned for reentry back to Earth. A Capsule Parachute Assembly System (CPAS) is being developed for preliminary parachute drop tests at the Yuma Proving Ground (YPG) to simulate high-speed reentry to Earth from beyond Low-Earth-Orbit (LEO) and to provide measurements of landing parameters and parachute loads. The avionics systems on CPAS also provide mission critical firing events to deploy, reef, and release the parachutes in three stages (extraction, drogues, mains) using mortars and pressure cartridge assemblies. In addition, a Mid-Air Delivery System (MDS) is used to separate the capsule from the sled that is used to eject the capsule from the back of the drop plane. Also, high-speed and high-definition cameras in a Video Camera System (VCS) are used to film the drop plane extraction and parachute landing events. To verify Electromagnetic Compatibility (EMC) of the CPAS system from unintentional radiation, Electromagnetic Interference (EMI) measurements are being made inside a semi-anechoic chamber at NASA/JSC at 1m from the electronic components of the CPAS system. In addition, EMI measurements of the integrated CPAS system are being made inside a hanger at YPG. These near-field B-Dot probe measurements on the surface of a parachute simulator (DART) are being extrapolated outward to the 1m standard distance for comparison to the MIL-STD radiated emissions limit.

Norgard, John D.↗
NASA NTRS2008

Designing the Ares I Crew Launch Vehicle Upper Stage Element and Integrating the Stack at NASA's Marshall Space Flight Center

Fielding an integrated launch vehicle system entails many challenges, not the least of which is the fact that it has been over 30 years since the United States has developed a human-rated vehicle - the venerable Space Shuttle. Over time, whole generations of rocket scientists have passed through the aerospace community without the opportunity to perform such exacting, demanding, and rewarding work. However, with almost 50 years of experience leading the design, development, and end-to-end systems engineering and integration of complex launch vehicles, the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center offers the in-house talent - both junior- and senior-level personnel - to shape a new national asset to meet the requirements for safe, reliable, and affordable space exploration solutions. The technical personnel are housed primarily in Marshall's Engineering Directorate and are matrixed into the programs and projects that reside at the rocket center. Fortunately, many Apollo-era and Shuttle engineers, as well as those who gained valuable hands-on experience in the 1990s by conducting technology demonstrator projects such as the Delta-Clipper Experimental Advanced, X-33, X-34, and X-37, as well as the short-lived Orbital Space Plane, work closely with industry partners to advance the nation's strategic capability for human access to space. The Ares Projects Office, resident at Marshall, is managing the design and development of America's new space fleet, including the Ares I, which will loft the Orion crew capsule for its first test flight in the 2013 timeframe, as well as the heavy-lift Ares V, which will round out the capability to leave low-Earth orbit once again, when it delivers the Altair lunar lander to orbit late next decade. This paper provides information about the approach to integrating the Ares I stack and designing the upper stage in house, using unique facilities and an expert workforce to revitalize the nation's space exploration resources.

Otte, Neil E.↗
NASA NTRSDate not supplied

Nomenclature for the OSIRIS-REx Returned Sample Collection to be Curated at NASA Johnson Space Center

The Origins, Spectral Interpretation, Resource Identification, and Security–Regolith Explorer (OSIRIS-REx) space-craft collected material from the asteroid Bennu on October 20, 2020. The OSIRIS-REx Sample Return Capsule (SRC) is planned to return to Earth on September 24, 2023. The OSIRIS-REx returned sample collection to be curated at NASA Johnson Space Center (JSC) will include both the asteroid material and the flight hardware. We expect most of the asteroid material to be inside the head of the Touch-and-Go Sample Acquisition Mechanism (TAGSAM), and that this material will include a broad range of particles sizes from as large as a few centimeters to less than a micrometer across in their longest dimension. In addition, asteroid material may have been returned along with the flight hardware: intentionally by the contact pads or screens on the witness plates, or serendipitously wedged into or adhering to hardware items. The nomenclature for this new astromaterials collection must accommodate the different types of samples it comprises.

asteroid↗
NASA NTRS1973

Fabrication of capsule assemblies, phase 3

Thirteen capsule assemblies were fabricated for evaluation of fuel pin design concepts for a fast spectrum lithium cooled compact space power reactor. These instrumented assemblies were designed for real time test of prototype fuel pins. Uranium mononitride fuel pins were encased in AISI 304L stainless steel capsules. Fabrication procedures were fully qualified by process development and assembly qualification tests. Instrumentation reliability was achieved utilizing specially processed and closely controlled thermocouple hot zone fabrication and by thermal screening tests. Overall capsule reliability was achieved with an all electron beam welded assembly.

Keeton, A. R.↗
NASA NTRS2015

Development of a Climatology of Vertically Complete Wind Profiles from Doppler Radar Wind Profiler Systems

Assessment of space vehicle loads and trajectories during design requires a large sample of wind profiles at the altitudes where winds affect the vehicle. Traditionally, this altitude region extends from near 8-14 km to address maximum dynamic pressure upon ascent into space, but some applications require knowledge of measured wind profiles at lower altitudes. Such applications include crew capsule pad abort and plume damage analyses. Two Doppler Radar Wind Profiler (DRWP) systems exist at the United States Air Force (USAF) Eastern Range and at the National Aeronautics and Space Administration's Kennedy Space Center. The 50-MHz DRWP provides wind profiles every 3-5 minutes from roughly 2.5-18.5 km, and five 915-MHz DRWPs provide wind profiles every 15 minutes from approximately 0.2-3.0 km. Archived wind profiles from all systems underwent rigorous quality control (QC) processes, and concurrent measurements from the QC'ed 50- and 915-MHz DRWP archives were spliced into individual profiles that extend from about 0.2-18.5 km. The archive contains combined profiles from April 2000 to December 2009, and thousands of profiles during each month are available for use by the launch vehicle community. This paper presents the details of the QC and splice methodology, as well as some attributes of the archive.

Barbre, Robert, Jr.↗
NASA NTRS2017

Capsulation Satellite or CapSat: A Low-Cost, Reliable, Rapid-Response Spacecraft Platform

The National Aeronautics and Space Administration (NASA) Goddard's Rideshare Office estimates that between 2013 and 2022, NASA launches of primary satellites will have left unused more than 20,371 kilograms of excess capacity. This equates to hundreds of millions of dollars in launch-vehicle costs going unutilized. To fill this void with a standard CubeSat or SmallSat spacecraft platform, which when required to be more reliable, still will cost in the neighborhood of $1M a kilogram, making it prohibitively expensive. A newly proposed solution, which NASA is pursuing, is called the Capsulation Satellite or CapSat. CapSat is a modularized, pressurized, thermally controlled spacecraft designed to host ruggedized commercially available instrumentation in a terrestrial like environment on orbit. Using a technique that is under review for a patent, CapSat actively manages internal air temperatures in a manner similar to a household thermostat. This gives CapSat high-thermal stability, which, in turn, provides component longevity. CapSat was specifically designed to take advantage of the United States Air Force (USAF) Rideshare Program and the Evolved Expendable Launch Vehicle Secondary Payload Adaptor, or ESPA ring. The ESPA ring comes in two sizes: standard and Grande. CapSat primarily will take advantage of the ESPA Grande to provide a 300-kilogram payload capability per attachment point, with up to four attachment points per ring. This approach combines a high-mass capability with a proven Rideshare mechanical interface and secondary payload management infrastructure. Opportunities for ESPA based co-manifests are continuing to expand. The CapSat program is currently funded to design and build a limited prototype and perform thermal-vacuum testing. CapSat is currently in the concept/study phase for both single missions and constellation of earth- and space-observing missions. One of these studies includes land imaging using state-of-the-art advanced infrared detector technology. This paper will report on the current status of the CapSat hardware design, testing, and results as well as any openly available advanced concept study results. The CapSat solution is intended to be a game-changing paradigm shift. CapSat will repurpose currently available, already-proven technology to reduce spaceflight hardware costs to less than $50,000 per kilogram.

Burt, Joe↗
NASA NTRS2017

Guidance Scheme for Modulation of Drag Devices to Enable Return from Low Earth Orbit

Passive drag devices provide opportunities to return payloads from low Earth orbits quickly without using onboard propulsive systems to de-orbit the spacecraft. However, one potential disadvantage of such systems has been the lack of landing accuracy. Drag modulation or changing the shape of the drag device during flight offer a way to control the de-orbit trajectory and target a specific landing location. This paper discusses a candidate passive drag based system, called Exo-brake, as well as efforts to model the dynamics of the vehicle as it de-orbits and guidance schemes used to control the trajectory. Such systems can enable quick return of payloads from low Earth orbit assets like the International Space Station without the use of large re-entry cargo capsules or propulsive systems.

Dutta, Soumyo↗
NASA NTRSDate not supplied

The Comet Astrobiology Exploration Sample Return (CAESAR) Mission

The Comet Astrobiology Exploration Sample Return (CAESAR) mission will acquire and return to Earth for laboratory analysis a minimum of 80 grams of surface material from the nucleus of comet 67P/Chur-yumov-Gerasimenko (67P). CAESAR will characterize the surface region sampled, preserve the collected sample in a pristine state, and return evolved volatiles by capturing them in a separate gas reservoir. NASA Goddard Space Flight Center provides project management, systems engineering, safety and mission assurance, contamination control, mission operations, and many other important functions. Northrop Grumman Space Systems will build the spacecraft, based on Dawn mission heritage, which like CAESAR, uses solar electric propulsion. CAESAR was selected by for Phase A study in the New Frontiers 4 Competition and will be proposed to New Frontiers 5.Collection of a sample from the surface of comet 67P is facilitated by a set of cameras that together provide images to support sample site selection, perform optical navigation, and document the sample before, during, and after col-lection. The sample is collected at the end of an arm during a 5-second touch-and-go (TAG) maneuver with the Sample Acquisition System (SAS)designed by Honeybee Robotics for the surface properties of comet 67P observed by the Rosetta mission. After sample collection, and while the sample is still cold (< -80°C), the TAG Arm inserts the sample container into the Sample Containment System (SCS) mounted inside the Sample Return Capsule (SRC). The SCS is sealed, preventing the sample from escaping into space. The sample is slowly warmed inside the SCS to enable sublimation of volatiles, which are collected in the Gas Containment System (GCS), a passively cooled gas reservoir. Separating the volatiles from the solid sample protects the solid sample from alteration. Once all sublimated H2O is transferred to the GCS, the GCS is sealed to capture the volatile sit contains, and the SCS is vented to space to maintain the solid sample under vacuum. The SCS vent is closed before Earth entry to prevent atmospheric contamination. Detailed laboratory analyses of the sample from 67P will trace the history of volatile reservoirs, delineate the chemical pathways that led from simple interstellar species to complex molecules, constrain the evolution of the comet, and evaluate the role of comets in delivering water and prebiotic organics to the early Earth. CAESAR will achieve these goals by carrying out coordinated sample analyses that will link macroscopic properties of the comet with microscale mineralogy, chemistry, and isotopic studies of volatiles and solids. Most of the sample (≥75%) will be set aside for analyses by generations of scientists using continually advancing tools and methods, yielding an enduring scientific treasure that only sample return can provide. This presentation will review development conducted during NF4 Phase A and discuss the NF5 mission concept.

A G Hayes↗
NASA NTRS2014

Supporting Multiple Programs and Projects at NASA's Kennedy Space Center

With the conclusion of the shuttle program in 2011, the National Aeronautics and Space Administration (NASA) had found itself at a crossroads for finding transportation of United States astronauts and experiments to space. The agency would eventually hand off the taxiing of American astronauts to the International Space Station (ISS) that orbits in Low Earth Orbit (LEO) about 210 miles above the earth under the requirements of the Commercial Crew Program (CCP). By privatizing the round trip journey from Earth to the ISS, the space agency has been given the additional time to focus funding and resources to projects that operate beyond LEO; however, adding even more stress to the agency, the premature cancellation of the program that would succeed the Shuttle Program - The Constellation Program (CxP) -it would inevitably delay the goal to travel beyond LEO for a number of years. Enter the Space Launch System (SLS) and the Orion Multipurpose Crew Vehicle (MPCV). Currently, the SLS is under development at NASA's Marshall Spaceflight Center in Huntsville, Alabama, while the Orion Capsule, built by government contractor Lockheed Martin Corporation, has been assembled and is currently under testing at the Kennedy Space Center (KSC) in Florida. In its current vision, SLS will take Orion and its crew to an asteroid that had been captured in an earlier mission in lunar orbit. Additionally, this vehicle and its configuration is NASA's transportation to Mars. Engineers at the Kennedy Space Center are currently working to test the ground systems that will facilitate the launch of Orion and the SLS within its Ground Services Development and Operations (GSDO) Program. Firing Room 1 in the Launch Control Center (LCC) has been refurbished and outfitted to support the SLS Program. In addition, the Spaceport Command and Control System (SCCS) is the underlying control system for monitoring and launching manned launch vehicles. As NASA finds itself at a junction, so does all of its associated centers across the US. KSC has found itself at the blunt end of change as the entire center has transitioned from an operations mindset to a development mentality. The author of this paper has had the fortunate privilege and opportunity to be part of a transforming NASA during the fall months of 2014. The following is a high level account of projects that he had the chance to work on including the Spaceport Command and Control System, the Advanced Ground System and Maintenance Program Project, Customer Avionics Development & Analysis (CAIDA) Lab and Swamp Works.

Advanced Ground System Maintenance↗
NASA NTRS2015

Boundary Layer Transition and Trip Effectiveness on an Apollo Capsule in the JAXA High Enthalpy Shock Tunnel (HIEST) Facility

Computational assessments were performed to size boundary layer trips for a scaled Apollo capsule model in the High Enthalpy Shock Tunnel (HIEST) facility at the JAXA Kakuda Space Center in Japan. For stagnation conditions between 2 MJ/kg and 20 MJ/kg and between 10 MPa and 60 MPa, the appropriate trips were determined to be between 0.2 mm and 1.3 mm high, which provided kappa/delta values on the heatshield from 0.15 to 2.25. The tripped configuration consisted of an insert with a series of diamond shaped trips along the heatshield downstream of the stagnation point. Surface heat flux measurements were obtained on a capsule with a 250 mm diameter, 6.4% scale model, and pressure measurements were taken at axial stations along the nozzle walls. At low enthalpy conditions, the computational predictions agree favorably to the test data along the heatshield centerline. However, agreement becomes less favorable as the enthalpy increases conditions. The measured surface heat flux on the heatshield from the HIEST facility was under-predicted by the computations in these cases. Both smooth and tripped configurations were tested for comparison, and a post-test computational analysis showed that kappa/delta values based on the as-measured stagnation conditions ranged between 0.5 and 1.2. Tripped configurations for both 0.6 mm and 0.8 mm trip heights were able to effectively trip the flow to fully turbulent for a range of freestream conditions.

Kirk, Lindsay C.↗