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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 NTRS2010

Lightweight Material Patches Allow for Quick Repairs

Cornerstone Research Group Inc., of Dayton, Ohio, has been the recipient of 16 Small Business Innovation Research (SBIR) contracts with NASA with a variety of different focuses, including projects like creating inflatable structures for radio frequency antennas and, most recently, healable polymer matrix composites for future space vehicles. One of its earlier SBIR contracts, with Kennedy Space Center, led to the development of a new type of structural patch for a variety of consumer uses: Rubbn Repair, for automotive uses; and Rec Repair for the outdoors and adventure market. Both are flexible, heat-activated structural patches.

Source record↗
NASA NTRS2014

Lightweight Inflatable Solar Array: Providing a Flexible, Efficient Solution to Space Power Systems for Small Spacecraft

Affordable and convenient access to electrical power is critical to consumers, spacecraft, military and other applications alike. In the aerospace industry, an increased emphasis on small satellite flights and a move toward CubeSat and NanoSat technologies, the need for systems that could package into a small stowage volume while still being able to power robust space missions has become more critical. As a result, the Marshall Space Flight Center's Advanced Concepts Office identified a need for more efficient, affordable, and smaller space power systems to trade in performing design and feasibility studies. The Lightweight Inflatable Solar Array (LISA), a concept designed, prototyped, and tested at the NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama provides an affordable, lightweight, scalable, and easily manufactured approach for power generation in space or on Earth. This flexible technology has many wide-ranging applications from serving small satellites to soldiers in the field. By using very thin, ultraflexible solar arrays adhered to an inflatable structure, a large area (and thus large amount of power) can be folded and packaged into a relatively small volume (shown in artist rendering in Figure 1 below). The proposed presentation will provide an overview of the progress to date on the LISA project as well as a look at its potential, with continued development, to revolutionize small spacecraft and portable terrestrial power systems.

Johnson, Les↗
NASA NTRS2014

Lightweight Inflatable Solar Array: Providing a Flexible, Efficient Solution to Space Power Systems for Small Spacecraft

Affordable and convenient access to electrical power is critical to consumers, spacecraft, military and other applications alike. In the aerospace industry, an increased emphasis on small satellite flights and a move toward CubeSat and NanoSat technologies, the need for systems that could package into a small stowage volume while still being able to power robust space missions has become more critical. As a result, the Marshall Space Flight Center's Advanced Concepts Office identified a need for more efficient, affordable, and smaller space power systems to trade in performing design and feasibility studies. The Lightweight Inflatable Solar Array (LISA), a concept designed, prototyped, and tested at the NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama provides an affordable, lightweight, scalable, and easily manufactured approach for power generation in space or on Earth. This flexible technology has many wide-ranging applications from serving small satellites to soldiers in the field. By using very thin, ultraflexible solar arrays adhered to an inflatable structure, a large area (and thus large amount of power) can be folded and packaged into a relatively small volume (shown in artist rendering in Figure 1 below). The proposed presentation will provide an overview of the progress to date on the LISA project as well as a look at its potential, with continued development, to revolutionize small spacecraft and portable terrestrial power systems.

Johnson, Len↗
NASA NTRS2014

Planned Flight of the Terrestrial HIAD Orbital Reentry (THOR)

The Terrestrial HIAD Orbital Reentry (THOR) is planned for flight in 2016 as a secondary payload on an Orbital Sciences commercial resupply mission to the International Space Station. THOR will launch with its Hypersonic Inflatable Aerodynamic Decelerator (HIAD) stowed as a small cylinder between the second stage motor and the launch vehicle fairing. Once the Cygnus cargo vehicle has separated from the second stage, THOR will likewise separate, autonomously re-orient itself, perform a deorbit burn, then inflate the HIAD to a 3.5m diameter cone before atmospheric interface. THOR is a follow-on mission to the IRVE-3 flight test of 2012. The high energy of orbital reentry will allow THOR to demonstrate the performance of its improved, second-generation inflatable structure and flexible TPS materials, in a more energetic entry environment than previous suborbital test flights.This paper discusses the sequence of events planned to occur as part of the THOR mission. Specific topics will include the THOR mission concept, reentry vehicle design for the expected flight environment, the on-board sensors that will allow quantification of vehicle performance, and how we intend to retrieve the flight data from a reentry vehicle splashing down in international waters.

Dillman, Robert↗
NASA NTRS2015

Self Healing Coating/Film Project

Kennedy Space Center (KSC) has been developing self healing materials and technologies. This project seeks to further develop self healing functionality in thin films for applications such as corrosion protective coatings, inflatable structures, space suit materials, and electrical wire insulation.

Technology Portfolio System↗
NASA NTRS2015

Lightweight Innovative Solar Array (LISA): Providing Higher Power to Small Spacecraft

Affordable and convenient access to electrical power is essential for all spacecraft and is a critical design driver for the next generation of smallsats, including cubesats, which are currently extremely power limited. The Lightweight Innovative Solar Array (LISA), a concept designed, prototyped, and tested at the NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama provides an affordable, lightweight, scalable, and easily manufactured approach for power generation in space. This flexible technology has many wide‐ranging applications from serving small satellites to providing abundant power to large spacecraft in GEO and beyond. By using very thin, ultra‐flexible solar arrays adhered to an inflatable structure, a large area (and thus large amount of power) can be folded and packaged into a relatively small volume. The LISA array comprises a launch‐stowed, orbit‐deployed structure on which lightweight photovoltaic devices and, potentially, transceiver elements are embedded. The system will provide a 2.5 to 5 fold increase in specific power generation (Watts/kilogram) coupled with a >2x enhancement of stowed volume (Watts/cubic‐meter) and a decrease in cost (dollars/Watt) when compared to state‐of‐the‐art solar arrays.

Johnson, Les↗
NASA NTRS2015

Space Radiation Effects in Inflatable and Composite Habitat Materials

This Year 2 project provides much needed risk reduction data to assess solar particle event (SPE) and galactic cosmic ray (GCR) space radiation damage in existing and emerging materials used in manned low-earth orbit, lunar, interplanetary, and Martian surface missions. More specifically, long duration (up to 50 years) space radiation damage is quantified for materials used in inflatable structures (1st priority), and habitable composite structures and space suits materials (2nd priority). The data collected has relevance for nonmetallic materials (polymers and composites) used in NASA missions where long duration reliability is needed in continuous or intermittent radiation fluxes.

Waller, Jess↗
NASA NTRS2013

Optimization of the Orbiting Wide-Angle Light Collectors (OWL) Mission for Charged-Particle and Neutrino Astronomy

OWL [1] uses the Earth's atmosphere as a vast calorimeter to fully enable the emerging field of charged-particle astronomy with high-statistics measurements of ultra-high-energy cosmic rays (UHECR) and a search for sources of UHE neutrinos and photons. Confirmation of the Greisen-Zatsepin-Kuzmin (GZK) suppression above approx. 4 x 10(exp 19) eV suggests that most UHECR originate in astrophysical objects. Higher energy particles must come from sources within about 100 Mpc and are deflected by approx. 1 degree by predicted intergalactic/galactic magnetic fields. The Pierre Auger Array, Telescope Array and the future JEM-EUSO ISS mission will open charged-particle astronomy, but much greater exposure will be required to fully identify and measure the spectra of individual sources. OWL uses two large telescopes with 3 m optical apertures and 45 degree FOV in near-equatorial orbits. Simulations of a five-year OWL mission indicate approx. 10(exp 6) sq km/ sr/ yr of exposure with full aperture at approx. 6 x 10(exp 19) eV. Observations at different altitudes and spacecraft separations optimize sensitivity to UHECRs and neutrinos. OWL's stereo event reconstruction is nearly independent of track inclination and very tolerant of atmospheric conditions. An optional monocular mode gives increased reliability and can increase the instantaneous aperture. OWL can fully reconstruct horizontal and upward-moving showers and so has high sensitivity to UHE neutrinos. New capabilities in inflatable structures optics and silicon photomultipliers can greatly increase photon sensitivity, reducing the energy threshold for n detection or increasing viewed area using a higher orbit. Design trades between the original and optimized OWL missions and the enhanced science capabilities are described.

Optimization↗
NASA NTRS2016

HIAD Advancements and Extension of Mission Applications

The Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology has made significant advancements over the last decade with flight test demonstrations and ground development campaigns. The first generation (Gen-1) design and materials were flight tested with the successful third Inflatable Reentry Vehicle Experiment flight test of a 3-m HIAD (IRVE-3). Ground development efforts incorporated materials with higher thermal capabilities for the inflatable structure (IS) and flexible thermal protection system (F-TPS) as a second generation (Gen-2) system. Current efforts and plans are focused on extending capabilities to improve overall system performance and reduce areal weight, as well as expand mission applicability. F-TPS materials that offer greater thermal resistance, and ability to be packed to greater density, for a given thickness are being tested to demonstrated thermal performance benefits and manufacturability at flight-relevant scale. IS materials and construction methods are being investigated to reduce mass, increase load capacities, and improve durability for packing. Previous HIAD systems focused on symmetric geometries using stacked torus construction. Flight simulations and trajectory analysis show that symmetrical HIADs may provide L/D up to 0.25 via movable center of gravity (CG) offsets. HIAD capabilities can be greatly expanded to suit a broader range of mission applications with asymmetric shapes and/or modulating L/D. Various HIAD concepts are being developed to provide greater control to improve landing accuracy and reduce dependency upon propulsion systems during descent and landing. Concepts being studied include a canted stack torus design, control surfaces, and morphing configurations that allow the shape to be actively manipulated for flight control. This paper provides a summary of recent HIAD development activities, and plans for future HIAD developments including advanced materials, improved construction techniques, and alternate geometry concepts that will greatly expand HIAD mission applications.

Johnson, R. Keith↗
NASA NTRS2016

GCR and SPE Radiation Effects in Materials

This Year 3 project provides risk reduction data to assess galactic cosmic ray (GCR) and solar particle event (SPE) space radiation damage in materials used in manned low-earth orbit, lunar, interplanetary, and Martian surface missions. Long duration (up to 50 years) space radiation damage is being quantified for materials used in inflatable structures (1st priority), and space suit and habitable composite materials (2nd priority). The data collected has relevance for nonmetallic materials (polymers and composites) used in NASA missions where long duration reliability is needed in continuous or intermittent space radiation fluxes.

Waller, Jess↗
NASA NTRS2017

Bigelow Expandable Activity Module (BEAM) Monitoring System

What is Bigelow Expandable Activity Module (BEAM)? The Bigelow Expandable Activity Module (BEAM) is an expandable habitat technology demonstration on ISS; increase human-rated inflatable structure Technology Readiness Level (TRL) to level 9. NASA managed ISS payload project in partnership with Bigelow Aerospace. Launched to ISS on Space X 8 (April 8th, 2016). Fully expanded on May 28th, 2016. Jeff Williams/Exp. 48 Commander first entered BEAM on June 5th, 2016.

Wells, Nathan↗
NASA NTRS1997

Low Cost Large Space Antennas

The mobile communication community could significantly benefit from the availability of low-cost, large space-deployable antennas. A new class of space structures, called inflatable deployable structures, will becom an option for this industry in the near future.

low-cost↗
NASA NTRS2021

Effect of Urea Links in the Backbone of Polyimide Aerogels

Flexible, conformal polyimide aerogels with low density, good mechanical properties and high surface areas have attracted much attention for many potential applications such as lightweight antenna substrates, insulating materials for launch vehicles, inflatable structures, aircraft or space suits. Development and improvements to fabrication of polyimide aerogel thin films have been reported over the last decade to meet the needs of many of these applications. However, most starting materials are expensive. In this research, we utilized commercially available, low cost monomers including 4,4’-bis(4-aminophenoxy)propane (BAPP) and 3,3’,4,4’-benzophenone tetracarboxylic dianhydride (BTDA), and 4,4-methylene diphenyl di-isocyanate (MDI) in fabricating polyimide (PI) and polyimide-urea (PIU), which were then cross-linked with 1,3,5-tris(4-aminophenoxy)benzene (TAB). It was found that the addition of MDI into the PI chains not only maintained the flexibility of the aerogel films, but also enhanced the film casting, allowing the production on pilot scale. With the capability in producing robust films at affordable cost, application of the PIU aerogel films can be expanded to terrestrial goods such as winter clothing, or pipe wrapping, etc. In addition, the presence of only a small addition of the urea links in the polyimide chains in PIU aerogels led to lower shrinkage when compared to the corresponding PI aerogels, leading to lower density

Baochau N. Nguyen↗
NASA NTRSDate not supplied

Error Sources and Mitigation Strategies for Thermocouples Integrated in Flexible Thermal Protection System Materials

Brief Presenter Biography:Ruth Miller is an aer-ospace systems engineer in the Entry Systems and Ve-hicle Development Branch at NASA Ames Research Center.Introduction:The flexible thermal protection sys-tem (FTPS) on NASA’s Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) vehicle will be in-strumented with thermocouples (TCs) to measure the in-depth thermal response during entry into Earth’s atmos-phere[1, 2]. Accurate flight temperature measurements are critical for verifying vehicle performance during the flight test and reducing uncertainties in the thermal models.However,the deployable nature of inflatable decelerator technology presents challengesfor integrat-ing TCs, specifically the TCsneed to be compactableand cannot damage the FTPSnor the inflatable structure(IS).Unlike traditional rigid aeroshells, routing TCsthrough the thickness of the FTPS could cause signifi-cant damage during packing of the deployable aeroshellbecause the different layers may shift small amounts in relation to each other imparting strain on the TCsand FTPS materials. The LOFTID TCleads are routed from the measurement location back to the data acquisition system in the vehicle centerbody within the same FTPS layer that they are monitoring the temperature. This ap-proach eliminates the need to put holes in the FTPS lay-ers,butas a consequence,the insulated TCleads travel for an appreciable distance through a region that will expose them to high temperaturesand large thermal gra-dients.LOFTID’s TCswere baselined to be commercially available Type K TCswith a binder impregnated glass braid insulation. These TCswere chosen because they had been used successfully on IRVE-3 and in ground-based arc jet testing. Additionally, these TCsdid notdamage the FTPS nor IS during packing and deploy-ment testing. However, the glass braid insulation is only rated to a maximum continuous use temperature of 482ºC. For reference, the duration of the heat pulse on the LOFTID vehicle is on the order of minutes and themaximum predicted temperaturebeneaththe outermost FTPS layersis 1350ºC.Ground-based testing in a tube furnace at NASA Ames Research Centerwas conducted to determine if the baseline TCsrouted through FTPS samples would survive and provide accurate temperature measure-mentsat LOFTID flight-relevant temperatures[3].The test results showed large measurement errors occurred beginning at approximately 400°C due to conductive deposits on the TCinsulation electrically shorting the TCleads.The conductive deposits and thus electrical shorting weredetermined to be caused by twoerror sources:1.The organic binder on the TCinsulation carbon-izingin a high temperature, low oxygen envi-ronment2.Decomposition products from the FTPSperme-atingthe braided TC insulationFurther testing in the tube furnace demonstrated that heat cleaning the TCinsulation effectivelyremovedthe organic binder andeliminatedthe first error source.The second error sourcewas shown to be mitigated by the addition of amica wraparound each individual TCleadtoact as an impermeable barrier.To understand the applicability of theground-based tube furnace test results to flight,anarc jet testseriesat Boeing’s Large Core Arc Tunnel (LCAT) facilitywas conducted[4].The error sourcesand mitigation strate-giesidentified in the tube furnace testing were substan-tiatedin the arc jet testing.However, the arc jet testing also revealed three new error sources:1.Glass TCinsulation meltingwhich resultsin electrical shorting of the TCeither through di-rect contact between the two leads or through the electrically conductive FTPS materials2.TCwire meltingwhich results in a noisy and/or open-loop TCresponse3.Type K TCwire green-rotwhich results in large calibration errors Scope of the Presentation:This presentation will include a brief discussion onthe effect of electrical shorting on the output of a TC(i.e. how to identify elec-trical shorting in TCdataand what the associated erroris).The tube furnace and arc jet test resultswill be dis-cussedand the solutions LOFTID is implementing to mitigate the error sourcesidentified in the tube furnace and arc jet testingwill be presented.Additionally, futureresearch and development work to eliminateTCerror sourcesfor future missionswill be recommended.

R A Miller↗
NASA NTRSDate not supplied

Probabalistic Risk Analysis and Thermal Margin Process for an Inflatable Aeroshell

Uncertainties always exist in atmospheric entry aeroheating environments and the thermal response of thermal protection system (TPS) material. These uncertainties are mitigated in the design by ap-plying margin and factors of safety to the TPS. Entry vehicle TPS is often conservatively over-sized for the heat loads that are experienced along the entry trajectory by stacking worst-case scenarios together. Additionally, the current TPS design and margin process used by NASA offers very little insight into the risk of over-temperature during flight and the reliability of the heat shield performance [1,3]. A probabilistic margin process can be used to calculate the amount of TPS margin necessary to survive a given entry heat load at a specified level of risk [2,3,4]. The vehicle’s initial entry state (entry velocity, flight path angle, and entry mass) determines the expected atmospheric entry environmental conditions and resulting heat load that the entry vehicle will experience. If there is flexibility in the entry state, then this process can be used to select an appropriate combination of entry state parameters and TPS size to target a desired reentry reliability. This probabilistic margin process allows engineers to make informed aeroshell design, entry-trajectory design, and TPS performance risk trades while preventing excessive TPS margin from being applied. The probabilistic TPS margin process has been performed to determine TPS thickness and entry heating constraints given an acceptable risk level for the Low Earth Orbit Flight Experiment of an Inflatable Decelerator (LOFTID) flight project. The process is used in a manner to size the entry heat load for a given flexible TPS (FTPS) thickness so that it meets project reliability standards while allowing the FTPS and the underlying inflatable structure (IS) to be pushed to adequately high temperatures. Since the LOFTID project is an experimental flight demonstration, it is de-sired to drive the FTPS and IS to temperatures that cover a large range of their thermal response models’ applicability. This will allow the thermal response models to be better improved and validated post-flight using LOFTID’s extensive instrumentation embedded within the aeroshell. The presentation demonstrates how uncertainty analysis is carried out using an end-to-end Monte Carlo process where three separate Monte Carlo simulations are run in sequence. The first Monte Carlo simulation operates on the entry trajectory model to generate trajectory parameter dispersions that are fed into the second Monte Carlo simulation. The second Monte Carlo simulation operates on the aerothermodynamics model to generate aeroheating parameter dispersions that are fed into the third Monte Carlo simulation. The third Monte Carlo simulation operates on the FTPS material thermal response model to generate the final FTPS/IS thermal response dispersions. The end-to-end Monte Carlo simulation propagates the uncertainties of each model into the next to quantify the resulting uncertainty of the FTPS/IS thermal response. The fractional contributions of the uncertain parameters in the trajectory, aerothermal, and thermal response models to the variance in the FTPS/IS thermal response is determined as a byproduct of the Monte Carlo analysis. The structural uncertainty of the FTPS thermal response model is evaluated by flight relevant ground testing and model error analysis using test measurements. This probabilistic TPS margin process had never been applied to an entry vehicle and it is one of the LOFTID project’s goals to demonstrate its merits.

Steven A. Tobin↗
NASA NTRSDate not supplied

Overview and Performance of the LOFTID Instrumentation Suite

On November 10, 2022, NASA launched the Low-earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) vehicle as a secondary payload mounted inside the launch vehicle adaptor on an Atlas V out of the Vandenburg Space Force Base (VSFB). The primary payload, Joint Polar Satellite System-2 (JPSS-2), was delivered successfully to a sun synchronous trajectory shortly after launch, at which point the Centaur upper stage performed a burn to de-orbit the system. Once on the desired trajectory to enter the atmosphere the payload adaptor canister was ejected by the payload adapter separation system to expose the packed LOFTID vehicle, then the LOFTID aeroshell, a Hypersonic Inflatable Aerodynamic Decelerator (HIAD), was deployed and inflated as planned. The Centaur pointed the LOFTID vehicle to the desired attitude to enter the atmosphere, spun the assembly to roughly three rpm, and separated the reentry vehicle. The LOFTID vehicle entered the atmosphere over Alaska at >8km/sec and decelerated as designed demonstrating stable flight from hypersonic entry through subsonic parachute deployment. On-board visible light cameras captured the reactions of the heatshield through all phases of flight, and co-located infrared light cameras captured the temperature distribution of the aft side of the heat shield anchored to a distribution of thermocouples on the inflatable structure (IS) in the field of view. Thermocouples were also embedded in the forward side of the aeroshell both in the Flexible Thermal Protection System (FTPS) as well as the IS. Heat Flux Gages and Pressure Transducers measured the heating rate and surface pressure experienced by the rigid nose of the reentry vehicle. Loadcells measured the interface loads between the IS and the rigid centerbody. This paper will discuss many of the key instruments flown on the successful LOFTID technology demonstration mission and will provide some high level results, while pointing to more detailed papers on the post-flight analyses.

Gregory T Swanson↗
NASA NTRSDate not supplied

Overview and Performance of the LOFTID Instrumentation Suite

On November 10, 2022, NASA launched the Low-earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) vehicle as a secondary payload mounted inside the launch vehicle adaptor on an Atlas V out of the Vandenburg Space Force Base (VSFB). The primary payload, Joint Polar Satellite System-2 (JPSS-2), was delivered successfully to a sun synchronous trajectory shortly after launch, at which point the Centaur upper stage performed a burn to de-orbit the system. Once on the desired trajectory to enter the atmosphere the payload adaptor canister was ejected by the payload adapter separation system to expose the packed LOFTID vehicle, then the LOFTID aeroshell, a Hypersonic Inflatable Aerodynamic Decelerator (HIAD), was deployed and inflated as planned. The Centaur pointed the LOFTID vehicle to the desired attitude to enter the atmosphere, spun the assembly to roughly three rpm, and separated the reentry vehicle. The LOFTID vehicle entered the atmosphere over Alaska at >8km/sec and decelerated as designed demonstrating stable flight from hypersonic entry through subsonic parachute deployment. On-board visible light cameras captured the reactions of the heatshield through all phases of flight, and co-located infrared light cameras captured the temperature distribution of the aft side of the heat shield anchored to a distribution of thermocouples on the inflatable structure (IS) in the field of view. Thermocouples were also embedded in the forward side of the aeroshell both in the Flexible Thermal Protection System (FTPS) as well as the IS. Heat Flux Gages and Pressure Transducers measured the heating rate and surface pressure experienced by the rigid nose of the reentry vehicle. Loadcells measured the interface loads between the IS and the rigid centerbody. This paper will discuss many of the key instruments flown on the successful LOFTID technology demonstration mission and will provide some high level results, while pointing to more detailed papers on the post-flight analyses.

spacecraft design↗