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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 NTRS2002

New Cryogenic Optical Test Capability at Marshall Space Flight Center's Space Optics Manufacturing Technology Center

A new cryogenic optical testing capability exists at Marshall Space Flight Center's Space Optics Manufacturing Technology Center (SOMTC). SOMTC has been performing optical wavefront testing at cryogenic temperatures since 1999 in the X-ray Cryogenic Test Facility's (XRCF's) large vacuum chamber. Recently the cryogenic optical testing capability has been extended to a smaller vacuum chamber. This smaller horizontal cylindrical vacuum chamber has been outfitted with a helium-cooled liner that can be connected to the facility's helium refrigeration system bringing the existing kilowatt of refrigeration capacity to bear on a 1 meter diameter x 2 meter long test envelope. Cryogenic environments to less than 20 Kelvin are now possible in only a few hours. SOMTC's existing instruments (the Instantaneous Phase-shifting Interferometer (IPI) from ADE Phase-Shift Technologies and the PhaseCam from 4D Vision Technologies) view the optic under test through a 150 mm clear aperture BK-7 window. Since activation and chamber characterization tests in September 2001, the new chamber has been used to perform a cryogenic (less than 30 Kelvin) optical test of a 22.5 cm diameter x 127 cm radius of curvature Si02 mirror, a cryogenic survival (less than 30 Kelvin) test of an adhesive, and a cryogenic cycle (less than 20 Kelvin) test of a ULE mirror. A vibration survey has also been performed on the test chamber. Chamber specifications and performance data, vibration environment data, and limited test results will be presented.

Kegley, Jeff↗
NASA NTRS1981

Survey of the US materials processing and manufacturing in space program

To promote potential commercial applications of low-g technology, the materials processing and manufacturing in space program is structured to: (1) analyze the scientific principles of gravitational effects on processes used in producing materials; (2) apply the research toward the technology used to control production process (on Earth or in space, as appropriate); and (3) establish the legal and managerial framework for commercial ventures. Presently federally funded NASA research is described as well as agreements for privately funded commercial activity, and a proposed academic participation process. The future scope of the program and related capabilities using ground based facilities, aircraft, sounding rockets, and space shuttles are discussed. Areas of interest described include crystal growth; solidification of metals and alloys; containerless processing; fluids and chemical processes (including biological separation processes); and processing extraterrestrial materials.

Mckannan, E. C.↗
NASA NTRS1977

Space Resources and Space Settlements

This publication contains the technical papers from the five task groups that took part in the 1977 Ames Summer Study on Space Settlements and Industrialization Using Nonterrestrial Materials. The study was sponsored by the following NASA Headquarters organizations: Office of Space Science, Office of Aeronautics and Space Technology, and Office of Space Transportation Systems. The NASA Ames Research Center hosted the study and provided administrative support through its Life Sciences Directorate. Expert assistance in the many aspects of the study came from NASA Headquarters, NASA centers, universities, industry, and from individual consultants. This summer study was the largest and most comprehensive investigation of space manufacturing and habitation to date; forty senior research workers and ten students participated. The six-week study was preceded by several months of planning and preparation, and was followed by extensive work on manuscript checking, review, and assembly. The study topics reflected the research areas requiring the most intensive attention as ofrnid-1977; they were: Group I: Regenerative life-support systems and controlled environment agriculture. Group II: Parametric studies of efficient habitats in space. Time and cost analysis of a space manufacturing program plan. Group III: Detection and analysis of special classes of asteroids suitable as material resources for space manufacturing; studies of retrieval missions. Group IV: Electromagnetic mass drivers for use as interorbital engines, as devices to launch lunar material into space, and as tugs for the retrieval of asteroidal material. Group V: Chemical processing of non terrestrial material in space; manufacture of metals and glass fibers, beneficiation, and design of processing plants. These five task groups each produced two or more technical papers, signed by the contributing members. The papers were subjected to independent peer review by scientists not connected with the study. During the course of the study, frequent formal and informal exchanges of information occurred between task groups, so that the entire effort evolved in a coherent fashion and was directed toward common goals. However, each group remained responsible for the choice of its topics and for its conclusions. A listing of all the participants is given on pages vii-x. It would be inappropriate for me to single out particular people or groups for special mention, since all involved applied their skills with dedication and enthusiasm. Instead, I thank everyone for their contributions to the success of the study, and also for making it a united and warmly cooperative personal experience.

John Billingham↗
NASA NTRSDate not supplied

SIBatt-3D: In-Space/On-Surface 3D Printing of Sodium Ion Batteries from ISRU Materials

Constructed more than 20 years ago, the International Space Station’s primary power system originally used nickel-hydrogen batteries with a lifetime of 6.5 years, until NASA began the process of replacing them in 2016 with lithium-ion batteries with a lifetime of 10 years. The demanding and costly process was accomplished after four flights of the Japanese H-II Transfer Vehicle cargo spacecraft (with a cost of about $10,000 per pound of payload), and 13 different astronauts conducting 14 spacewalks. Besides utilization in the ISS, rechargeable batteries are present in many space applications: they are installed in exploration robots, life support systems and in portable communication devices, to mention some. In this context, this project is focused on the in-space manufacturing of shape-conformable batteries using in-situ resources, and aims to address the NASA’s gaps related to the development of next generation of energy storage devices (TX03), as well as in-space manufacturing and in-situ resource utilization (TX07). The proposed work also tackles the HEOMD’s objectives targeting the in-space additive manufacturing (AM) from Lunar/Martian materials (regolith as AM feedstock) to reinvigorate America’s Human Space Exploration Program (SPD-1). This project is in direct alignment with the STMD’s objectives to demonstrate in-space autonomous manufacturing and assembly of complete systems by 2030, and to enable humans to live and explore in space and on planetary surfaces by 2040 thanks to in-space habitation, infrastructure development and in-situ resource utilization (ST1 and ST5). Manufacturing of shape conformable batteries directly in-space and using in-situ resources would also contribute to reducing the payload weight and volume (TX12) for future missions, thus reducing risk for long term Mars missions where rapid resupply is logistically infeasible. Nowadays, commercial batteries consist of stacked two-dimensional (2D) sheets, which are only manufactured in restricted geometries (cylindrical and coin cell). Evolving from conventional 2D, complex 3D battery architectures have been proven to increase the electrochemical active surface area and ion diffusion path, leading to improved areal energy density and power performance. This tendency was illustrated in our recent in-depth modeling studies by simulating a classical Ragone plot exhibiting the energy-power relationship. Our team demonstrated through modeling that a complex gyroidal 3D printed battery architecture exhibits significantly improved power performances (>150% at the current density of 6C; full discharge in 10 minutes) in comparison to a traditional 3D printed planar geometry. Motivated by these results and as the fabrication of intricate 3D battery design is only possible experimentally thanks to the geometric freedom offered by additive manufacturing (AM), our team has already initiated leveraging thermoplastic material extrusion at the laboratory scale. While 3D printing of batteries is relatively recent (2013), it has witnessed a growing interest during the last recent years, as next-generation shape-conformable 3D batteries can be co-designed with the system. Consequently, dead-volume and mass brought from Earth are minimized, in addition to improved battery performance, in alignment with the aforementioned NASA’s objectives. Further, while this project is specifically dedicated to batteries, it lends itself towards the maturation of in-space manufacturing via 3D printing using in-situ resources, stated in HEOMD and STMD goals.

In-Space Manufacturing↗
NASA NTRSDate not supplied

Reversibly Assembled Microparticles for Sustained Applications on the Moon and Mars

A sustained presence in any extra-terrestrial environment will require the capability to generate materials, goods, and ultimately vehicles, construction supplies and habitats to be tenable. As an example, NASA, in collaboration with Made In Space, Inc., recently reported the results of extensive research toward enabling3D printing in space. The extensive characterization and comparison of 3D printed articles suggested that, overall, articles generated in the International Space Station microgravity environment were comparable to those generated on Earth. The benefit of in-space manufacturing can be increased through utilization of recyclable materials. A recent analysis of a hypothetical 1,100 day round trip mission to Mars determined that significant mass savings and increase in mission probability of success could be achieved through in-space manufacturing with recyclable materials. NASA’s project ESPUR (Enabling Sustained Presence Using Recyclables), through support from NASA Langley’s Innovative Research and Development Fund, is investigating novel, polymer-coated, epoxy microparticle systems as an enabling technology to realize in-space manufacturing using recyclable feedstocks. Building from previously reported results, further progress toward synthesis of the polymer coating containing click chemical functionalities will be described here. Finite elemental analysis (FEA) has been utilized, in light of scale-free/small world considerations in an effort to identify compositions most likely to yield robust macroscopic geometries. Initial results will be described here. Finally, potential mass savings and life cycle of this recyclable materials technology will be discussed.

Click Chemistry↗
NASA NTRS2012

Cost-Effective Additive Manufacturing in Space: HELIOS Technology Challenge Guide

Welcome to the HELIOS Technology Challenge Guide. This document is intended to serve as a general road map for participants of the HELIOS Technology Challenge [HTC] Program and the associated inaugural challenge: HTC-01: Cost-Effective Additive Manufacturing in Space. Please note that this guide is not a rule book and is not meant to hinder the development of innovative ideas. Its primary goal is to highlight the objectives of the HTC-01 Challenge and to describe possible solution routes and pitfalls that such technology may encounter in space. Please also note that participants wishing to demonstrate any hardware developed under this program during any future HELIOS Technology Challenge showcase event(s) may be subject to event regulations to be published separately at a later date.

DeVieneni, Alayna↗
NASA NTRSDate not supplied

PRIME ISS Ground Prototype

In Additive Manufacturing (AM) with metal powders, layers of material are deposited and fused to form metal 3D parts. However, in most cases, remnant powder still must be removed from interior cavities and channels to fully clean the part before use. Ground demonstrations such as ultrasonic cleaning have been proven to work during ground testing at MSFC and Florida State University. However, manufacturing in the low gravity environment of space introduces challenges to this powder removal. Therefore, if this concept could be demonstrated in microgravity, the ability to clean AM parts or contaminated parts can bring new advancements to in-space manufacturing (ISM). The goal of this work was to make significant progress on developing an ISS payload using the ultrasonic technology called Powder Removal in Microgravity Environments (PRIME). This would also create new opportunities for in-space manufacturing (ISM) and the additive manufacturing community to develop new standards and practices for powder removal and the cleaning of contaminated parts in space.

Microgravity↗
NASA NTRS1975

Manufacturing in space and materials sciences on Skylab

Two main groups of manufacturing and materials studies were performed during the Skylab missions. The first group of experiments studied processes which are important in orbital assembly and construction, including melting, solidification, brazing, welding, and cutting. The second group concerned the manufacture of specific materials, including metallic alloys, single crystals, doped semiconductors, composite materials, and multicomponent superconductors. The present paper discusses several specific experiments conducted on Skylab. In general, the processes tested produced materials of higher quality in space than they would have on earth. The experiments prove that the elimination of gravitational forces has a decisive effect on a number of materials processes.

Stuhlinger, E.↗
NASA NTRS1975

Summary and recommendations

An economic analysis using econometric and cost benefit analysis techniques was performed to determine the feasibility of space processing of certain products. The overall objectives of the analysis were (1) to determine specific products or processes uniquely connected with space manufacturing, (2) to select a specific product or process from each of the areas of semiconductors, metals, and biochemicals, and (3) to determine the overall price/cost structure of each product or process considered. The economic elements of the analysis involved a generalized decision making format for analyzing space manufacturing, a comparative cost study of the selected processes in space vs. earth manufacturing, and a supply and demand study of the economic relationships of one of the manufacturing processes. Space processing concepts were explored. The first involved the use of the shuttle as the factory with all operations performed during individual flights. The second concept involved a permanent unmanned space factory which would be launched separately. The shuttle in this case would be used only for maintenance and refurbishment. Finally, some consideration was given to a permanent manned space factory.

Source record↗
NASA NTRS2012

Innovative Approaches to Space-Based Manufacturing and Rapid Prototyping of Composite Materials

The ability to deploy large habitable structures, construct, and service exploration vehicles in low earth orbit will be an enabling capability for continued human exploration of the solar system. It is evident that advanced manufacturing methods to fabricate replacement parts and re-utilize launch vehicle structural mass by converting it to different uses will be necessary to minimize costs and allow flexibility to remote crews engaged in space travel. Recent conceptual developments and the combination of inter-related approaches to low-cost manufacturing of composite materials and structures are described in context leading to the possibility of on-orbit and space-based manufacturing.

Hill, Charles S.↗
NASA NTRS2022

Research Campaign: Advanced Manufacturing in Space: Properties, Structure and Simulations to Pioneer New Applications

This topic underpins synthesis of, and in many cases manufacturing of, value-added materials via liquid phase processing. Materials and processes range from cast metals and optical glasses through exploration-relevant technologies such as additive manufacturing, casting and in-situ resource utilization to support human space exploration. A recurring theme is the need for accurate thermophysical property and atomic structure data for relevant materials and the exploitation of reduced convection/sedimentation in microgravity to enhance the quality of data and to develop new and transformative technologies for materials processing.

Michael SanSoucie↗
NASA NTRS1970

Manufacturing in space

Skylab Orbital Workshop fabrication experiments under space environment conditions, discussing weightlessness and vacuum effects on various manufacturing techniques

Wuenscher, H. F.↗
NASA NTRSDate not supplied

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity↗
NASA NTRS1972

Extraterrestrial imperative

The future benefits of extraterrestrial space to man and his problems, both personal and environmental, are discussed. Particular attention was given to space manufacturing, development of space power plants, mineral exploration, and transportation costs of such activities.

Ehricke, K. A.↗
NASA NTRS1976

OAST Space Theme Workshop. Volume 2: Theme summary. 1: Space power (no. 7). A. Theme statement. B. 26 April 1976 presentation. C. Summary. D. Initiative action

A long-lived space-based system that converts on-orbit solar and/or nuclear energy to a suitable form for distribution to using space systems is described. Mission applications, requirements, issues, problems, benefits, and technology thrusts are identified for the multipurpose power platform. Power levels of at least 10-100Kw are required for space manufacturing, satellites, and space station operations. Two Mw are needed for a proposed passive radar system. Propulsion system requirements are in the 100Kw-100Mw range.

Source record↗